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Repair Amp Alteration of Storage Tanks 141205170941 Conversion Gate02 PDF
Repair Amp Alteration of Storage Tanks 141205170941 Conversion Gate02 PDF
Repair Amp Alteration of Storage Tanks 141205170941 Conversion Gate02 PDF
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramcos
employees. Any material contained in this document which is not already
in the public domain may not be copied, reproduced, sold, given, or
disclosed to third parties, or otherwise used in whole, or in part, without
the written permission of the Vice President, Engineering Services, Saudi
Aramco.
Chapter : Vessels
File Reference: MEX20308
Engineering Encyclopedia
Vessels
Determining Requirements for Repair or Alteration of Storage Tanks
CONTENTS
PAGE
Engineering Encyclopedia
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Determining Requirements for Repair or Alteration of Storage Tanks
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HYDROTESTING REQUIREMENTS THAT ARE SPECIFIED IN SAESA-004 AND API-653 ...................................................................................................... 109
SAES-A-004 Requirements ......................................................................................... 109
API-653 Requirements................................................................................................. 109
WORK AID 1: PROCEDURE FOR DETERMINING REPAIR OR
ALTERATION REQUIREMENTS FOR SITUATIONS INVOLVING
STORAGE TANK SHELLS AND SHELL PENETRATIONS ...................................... 111
Work Aid 1A: Procedural Steps.................................................................................. 111
Work Aid 1B: Inspection Data.................................................................................... 112
Tank Shell ................................................................................................................. 112
Tank Shell Penetrations............................................................................................. 117
Work Aid 1C: Reference to Pertinent Content From SAES-D-108 ............................ 118
Tank Shells................................................................................................................ 118
Tank Shell Penetrations............................................................................................. 118
Work Aid 1D: Reference to Pertinent Content From API-653 ................................... 119
Tank Shells................................................................................................................ 119
Tank Shell Penetrations............................................................................................. 126
WORK AID 2: PROCEDURE FOR DETERMINING REPAIR OR
ALTERATION REQUIREMENTS FOR STORAGE TANK BOTTOMS ..................... 128
Work Aid 2A: Inspection Data.................................................................................... 128
Work Aid 2B: Reference to Pertinent Content From SAES-D-108 ............................ 129
Work Aid 2C: Reference to Pertinent Content From API-653.................................... 130
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Determining Requirements for Repair or Alteration of Storage Tanks
Hot taps
Nondestructive examinations
Hydrostatic testing
Any conflicts between SAES-D-108 and other Saudi Aramco engineering documents must be
resolved by the Saudi Aramco Manager of the Consulting Services Department at Dhahran.
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Determining Requirements for Repair or Alteration of Storage Tanks
API-653
API-653 is the industry standard that applies to the repair and maintenance of existing
atmospheric storage tanks. The scope of API-653 is as follows:
API-653 applies to carbon and low-alloy steel tanks that were built in
compliance with the requirements of API-650, Welded Steel Tanks for Oil
Storage, and its predecessor API-12C, API Specification for Welded Oil
Storage Tanks.
The majority of tanks will be of carbon steel construction.
API-653 is limited to the foundation, the bottom, the shell, the structure, the
roof, attached appurtenances, and nozzles up to the face of the first flange, the
first threaded joint, or the first welded-end connection.
These components are the primary components that relate to the tank's
structural integrity and/or could have a significant environmental impact should
their condition not be acceptable.
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API-653
Original construction standard
Current edition of original construction standard
API-650
API-653 is not a design standard for new tank construction. However, API-653 applies some
API-650 requirements within its procedures. In addition, API-653 requirements still must be
considered in new tank design because API-653 requirements can affect several design
decisions that must be made. For example, API-653 specifies minimum acceptable bottom
plate thickness requirements after a tank has been in service. In certain situations, the
minimum acceptable bottom plate thickness may require the use of a thicker bottom plate for
a new tank than API-650 requires as a minimum. The thicker bottom plate may be needed in
order to have an acceptable tank bottom inspection interval and design life.
API-653 is intended for use by qualified engineering and inspection personnel who are
experienced in the design, fabrication, repair, construction, and maintenance of storage tanks.
In cases where API-653 (or API-650 or API-12C) does not contain appropriate requirements
for a specific situation, the intent is to provide tank integrity that is equivalent to current API650 requirements.
Many owner companies have used internally developed inspection, repair, and maintenance
practices prior to the introduction of API-653. Now that API-653 exists, it must be
considered by all companies that have atmospheric storage tanks. Companies that have
established tank inspection, repair, and maintenance procedures should review them with
respect to API-653. Companies that have less formal procedures will be under increased
pressure to meet API-653 requirements as a minimum.
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Internal or external corrosion. For example, has the shell corroded to the point
where it is no longer structurally sound? Is the bottom in danger of "holing
through" and leaking?
Actual stress levels in comparison to allowable values. Has the shell corroded
to the point where its stresses are higher than acceptable stresses?
Properties of the stored liquid, such as its specific gravity, temperature, and
corrosivity. Has there been a change in service such that the new liquid that is
being stored has a higher specific gravity, is being stored at a temperature that
is over 93C (200F), or is more corrosive than the liquid that the tank was
originally designed to store?
Design metal temperature. Has the tank service changed such that a lower
design metal temperature must be considered than was used in the original
design?
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External roof live load, wind, seismic load. Has there been sufficient
deterioration in the tank such that these other design loads must also be
considered in assessing the tank's structural integrity?
Distortions in the shell or roof. These distortions might indicate that there have
been problems with excessive internal or external pressures. Such problems
could be caused by higher than design filling or emptying rates or by improper
vent operation.
The suitability for service of a storage tank is assessed by evaluating the current condition of
the tank's primary structural components with respect to API-653 acceptance criteria. The
primary structural components that are evaluated are those structural components that directly
affect the tank's capability to store liquid. These components are as follows:
Roof
Shell
Bottom
Foundation
Para. 2.4 of SAES-D-108 modifies the suitability-for-service requirements that are contained
in API-653 with respect to assessment of the bottom. Saudi Aramco accepts the other API653 suitability-for-service requirements.
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Storage tank alterations are required when the service requirements for the tank are changed.
Typical examples of storage tank alterations are as follows:
Addition of manways or nozzles that are over 300 mm (12 in.) in nominal size
Section 7 of API-653 specifies requirements for tank repair and alteration for the following
areas:
Hot taps
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Section 7 of SAES-D-108 modifies the repair and alteration requirements that are contained in
API-653 in the following areas:
Hot taps
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One of the prime factors that initiated the preparation of API-653 was a catastrophic brittle
fracture of a fuel oil storage tank that occurred in the late 1980's in the U.S. This failure
occurred the first time that the tank was filled after it had been reconstructed, and it resulted in
a major fuel oil discharge into a nearby river. Therefore, the reconstruction requirements that
are contained in Sections 5, 6, and 8 of API-653 are conservative, especially those
requirements that relate to the reuse of existing material. These requirements cover:
SAES-D-108 does not modify any API-653 requirements with respect to dismantling and
reconstruction.
Hot Tapping
A "hot tap" or "hot tapping" refers to the procedure that is used to add a new nozzle to a
storage tank, pipe, or pressure vessel without taking the storage tank, pipe, or pressure vessel
out of service. Adding a nozzle by hot tapping is sometimes advantageous because of
operational considerations. Adding nozzles by hot tapping is not an uncommon practice,
especially in piping systems. However, since there are inherent risks associated with adding
nozzles while a storage tank or pipe is still in service, this procedure should only be used
where it is impractical to take the tank or pipe out of service.
A hot tap is performed by:
Welding a suitably sized and reinforced nozzle to the tank. This nozzle has a
flanged end.
Bolting a full-port valve to the flanged nozzle, and bolting a hot tap machine to
the valve.
Opening the valve and using the hot tap machine cutter to cut an opening in the
tank and to hold the cut piece.
Extracting the cut piece of plate, called the "coupon," through the valve and
into the cutting machine housing.
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Figure 1 illustrates the basic arrangement for making a hot tap. A new pipe section,
instrument, or equipment item can then be bolted onto the flanged valve as required.
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API-653 Requirements - API-653 contains hot tap requirements in Para. 7.13. Several of
these requirements are summarized in the paragraphs that follow. Course Participants are
referred to API-653 for additional information.
API-653 contains requirements for radial nozzle installation, which is the most
common orientation. If a nonradial nozzle must be installed by hot tapping,
additional requirements must be developed. These additional requirements
may entail items such as:
-
Further inspection
The roof or within the tank vapor space. A flammable mixture may
form in this area, and it may be ignited by the heat from the hot tap
cutting or welding operations.
Laminated or badly pitted shell plate. This restriction ensures that the
hot tap will be made only into a sound area of the tank shell. Sufficient
visual, pit gauge, and ultrasonic inspection measurements must be made
to ensure that the tank shell thickness and integrity are adequate for the
hot tap. The hot tap must be relocated as needed to a sound area on the
tank.
Connection size and shell plate thickness limitations are as provided in Figure
2:
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mm
in.
mm
in.
200
6.35
1/4
355
14
9.5
3/8
460
18
12.7
1/2
The minimum spacing in any direction between the hot tap and adjacent
nozzles shall be at least Rt where "R" is the tank radius and "t" is the tank
shell plate thickness. The Rt spacing is measured toe-to-toe between the
welds. This minimum spacing requirement is to avoid excessive localized
stresses that might develop due to the proximity of geometric discontinuities.
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Only steels that are of known acceptable fracture toughness may be hot tapped.
One measure of meeting this requirement is if it is known that the steel met
current API fracture toughness requirements. Meeting current API fracture
toughness requirements means either that the steel was exempt from impact
testing, or that it was impact-tested at the design metal temperature.
Steels that are of unknown fracture toughness may be hot tapped if the
minimum shell metal temperature during the hot tap meets or exceeds the
exemption curve in Figure 7-5 of API-653 based on the plate thickness where
the hot tap is being done. In this case, the steel is known to have fracture
toughness that is sufficient to not have a brittle fracture while the hot tap is
being done.
API-653 requires that a hot tap procedure be developed and documented. The procedure
must be specific to the particular hot tap that is to be done. API-653 also requires that the hot
tap procedure include practices that are given in API Publication 2201, Procedure for
Welding or Hot Tapping on Equipment Containing Flammables. Several of these practices
are noted in the paragraphs that follow. Course Participants are referred to API-2201 for
additional information.
Service fluid characteristics that would make hot tapping unsafe must be
considered. These fluid characteristics include the following:
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Tank operations must be stopped during the hot tapping. For example:
-
Turn off all heating coils during hot tapping. Turning off the coils will help to
dissipate the heat that is generated by the cutting and welding operations.
Maintain a liquid level of at least 1 m (3 ft.) above the hot work area when
welding or cutting is being done. This liquid level will help to dissipate the
heat that is generated, and it will help to keep the hot tapping sufficiently below
the vapor space.
In general, hot work should not be done on either the deck or pontoons of a
floating roof tank due to the likelihood that a flammable mixture will be present
under the deck.
Owner companies such as Saudi Aramco typically have their own detailed hot tap procedures
and restrictions that build upon the API-653 and API-2201 requirements. Saudi Aramco
requirements are highlighted in the section that follows.
SAES-D-108 Requirements - SAES-D-108 requires that a stress analysis be performed for
hot taps that are larger than 460 mm (18 in.) pipe size. Recall that API-653 minimum
acceptable shell thickness requirements stop at this pipe size. Therefore, Saudi Aramco
would permit larger diameter hot taps, but they are treated as special cases. The Consulting
Services Department should be consulted for these situations.
SAES-D-108 refers to Saudi Aramco General Instruction G.I. 441.010, Installation of Hot
Tapped Connections, for requirements that are related to installation procedures,
organizational responsibilities for various phases of the work, and safety considerations. The
detailed emphasis of G.I. 441.010 is on hot taps that are made into piping systems because
these comprise the vast majority of all of the hot taps that are made. However, the overall
safety and procedural requirements that are contained in G.I. 441.010 apply to storage tank
hot taps as well. The paragraphs that follow highlight the primary organizational
responsibilities for hot taps. Participants are referred to G.I. 441.010 for detailed information.
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Development of the required design details and drawings for the hot tap
connection and reinforcement
Design calculations
Inspection for the thickness and condition of the tank shell plate in the area
where the welding will be done.
Inspecting the connection before and during the installation for compliance
with the specifications.
Witnessing and approving the hydrotests of the hot tap valve and the installed
nozzle.
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Leaks
Shell distortion
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Early identification of problems such as those listed above and their causes can help in the
development of appropriate corrective action, it can prevent more extensive damage, and it
can direct the planning efforts for later internal inspections and maintenance activities.
Periodic internal inspection of the tank is also required to identify potential problems that are
not visible from the outside of the tank. The following are several reasons for doing an
internal tank inspection:
To gather sufficient data to perform shell and bottom plate minimum thickness
assessments that are part of the required suitability for service evaluation.
To identify locally corroded areas of the shell that were not identified by any
external inspection that was done.
Figure 3 (in four parts) illustrates typical locations on a tank that must be inspected
periodically, and notes many of the types of deterioration that must be considered.
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Saudi Aramco sets tank inspection intervals based on SAEP-20 requirements rather than
based on API-653 requirements. API-653 also divides external inspection into routine inservice inspection and scheduled inspection. This concept of dividing the external inspection
and the general considerations that are contained in API-653 still apply with SAEP-20
inspection interval requirements.
Several factors that must be considered in the determination of suitable inspection intervals
are as follows:
Corrosion allowances and corrosion rates. What was anticipated as part of the
original design, and what has been the actual experience?
Methods and materials of construction and repair. Do the materials and repair
methods that were used meet current requirements?
Potential risk of air or water pollution. Is the tank near a major body of water
or residential area?
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Changes in operation. Have there been changes in the filling and emptying
frequency that would affect the reliability of tank components? For example, is
a floating roof being landed more frequently? Has the stored liquid been
changed to one that is more corrosive?
As stated earlier, storage tanks must be inspected at reasonable intervals to determine their
current condition and to permit assessment of their suitability for continued service. Saudi
Aramco develops tank inspection interval requirements based on procedures that are
contained in SAEP-20. SAEP-20 also contains procedures that must be followed to extend or
to deviate from the inspection intervals that were originally established, and it assigns
implementation responsibilities to specific Saudi Aramco organizational functions.
SAEP-20 requires that an Equipment Inspection Schedule (EIS) be developed for tanks that
are in the following categories:
Utilities, production, processing, storage, and transportation of oil, gas, and byproducts.
The EIS must be prepared, and it must be included in the Inspection Record Book as part of
the Project Record Book. The EIS must be submitted for approval 30 days prior to
completion of the facility.
The approval process involves Saudi Aramco Project
Management, the facility's Operations Engineering Unit, and the facility's Inspection Unit.
Therefore, all of the appropriate organizations are involved in the development of the EIS,
and they will provide relevant Saudi Aramco experience to this process.
SAEP-20 requires that inspection intervals be specified for both On-Stream Inspection (OSI)
and Test and Inspection (T&I). In both cases, initial inspection intervals (I-OSI and I-T&I)
and subsequent inspection intervals must be specified.
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SAEP-20 contains procedures that classify fixed equipment, including storage tanks, with
respect to Corrosion Service Classes. Table II of SAEP-20 defines four Corrosion Service
Classes based on corrosion rate (or special problems). The maximum OSI and T&I inspection
intervals are then determined, primarily based on these Corrosion Service Classes, and on
other factors that are stated in SAEP-20.
On-Stream Inspection (OSI)
The tank's external condition should be monitored by close visual inspection from the ground
on a routine basis by personnel who are familiar with storage tanks but who are not
necessarily qualified inspectors. For example, these routine visual inspections may be done
by operations or maintenance personnel who must be in the area as part of their primary job
function. The intent of the routine inspections is to identify questionable items that should be
examined in more detail by qualified inspectors.
Formal external inspections must be made by qualified inspection personnel on a scheduled
basis. The OSI interval is determined by criteria that are contained in SAEP-20. The required
OSI interval is determined based on the anticipated or measured corrosion rates, past
experience, and any findings that are obtained from the routine in-service inspections that
were made. Ultrasonic thickness measurements of the shell are a part of this inspection.
External nondestructive examination (NDE) that is done as part of the OSI provides
information that may be used to adjust T&I intervals that were initially specified, if
appropriate, based on actual inspection results. OSI can be done at any time. However, based
on Table II of SAEP-20, the maximum interval for the initial OSI for tanks will be in the
range of 12 to 24 months, based on the Corrosion Service Class of the tank. There is some
flexibility in setting this initial OSI interval, and the Area Operations Inspection Unit should
be consulted to finalize the initial OSI interval based on the general factors that were
previously noted.
Subsequent OSI intervals are determined using one of the following methods (based on Para.
3.5.7.2 of SAEP-20):
Calculated based on the remaining tank life using the results of prior
inspections. The maximum subsequent OSI interval that is determined on this
basis should be no more than the smaller of one-fourth of the remaining life, or
five years.
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Remaining Life. The subsequent T&I interval can be no more than the smaller
of half the calculated remaining tank life or ten years. The remaining life is
based on the existing (i.e., remaining) corrosion allowance divided by the
maximum corrosion rate that is determined by inspection data that were
obtained from the OSI or from prior experience.
Service Criteria. The subsequent T&I interval can be no more than that
determined from Table I of SAEP-20 based on the Corrosion Service Class.
This subsequent T&I interval will range between 30 and 120 months.
10 years for storage tanks and RLPG tanks at 17 kPa (2.5 psig) and less
(including water)
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Scope and History. This section specifies the scope of the current inspection as
well as the inspection methods that were used (such as visual observations and
ultrasonic measurements). The use of any special inspection techniques should
be documented.
This section also summarizes the tank's history, such as when it was placed into
service, when the last T&I was done, and any significant inspection findings or
repairs that were made during the last T&I. The Equipment Inspection
Schedule (EIS), with the associated On-Stream Inspection (OSI) and Test &
Inspection (T&I) intervals, are not a part of the Inspection and History Report,
but these items may be referred to if required as part of the evaluation.
The inspector should have reviewed the operating history of the tank, and he
should have identified any operating difficulties that occurred during the last
period of operation prior to the T&I. Anything unusual in the operating history
should be documented in the report because an operations factor might have
contributed to problems that are noted during the inspection. This tank history
review should also include whether any problems were found on similar tanks
during their T&Is that affected how the current inspection was conducted.
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The complete information file for the tank will include the Tank Data Sheet-Layout of
Appurtenances (Form 2696), the Safety Instruction Sheet (Form 2693), the contractor's tank
data specification sheet, fabrication drawings, and the mechanical design calculations. It may
be necessary to refer to this additional information in order to evaluate the current inspection
data. However, this additional information is not part of the Inspection and History Report.
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Observations/Recommendations
Shell
Wind Girder
Roof
Bottom
Coating
Nozzles and Flanges
Foundation
Paint System
Insulation System
Ladders, Stairways, Platforms
Auxiliary Equipment (Gage connections,
alarms, vents, etc.)
Grounding Connections
Cathodic Protection System
Figure 4. Components of Inspection and History Report
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Thickness Data
Point
Number
Original
Nominal
Thickness
Minimum
Required
Thickness
Measured Thickness
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Pitting Corrosion
Pitting corrosion is when the material has been removed in a very localized area, giving a
crater-like appearance to the surface. Pits can be very deep or shallow and be of varying
diameters. Pitting is not of great concern as a threat towards the overall integrity of the shell
unless the pits are present in close proximity to each other and unless they are very deep and
extensive. However, pits can result in local leaks if they progress through the entire shell
thickness.
Tank Shell Evaluation
Evaluation of shell corrosion consists of determining if the current condition of the shell is
adequate for the tank service. If a change in tank service is being considered, the shell must
be evaluated for the new service conditions. For example, if the stored liquid will be changed
to one with a higher specific gravity, the higher specific gravity must be considered in the
evaluation. The evaluation must consider all anticipated loading conditions and load
combinations, not necessarily just the hydrostatic pressure load. These conditions are the
same conditions that were originally considered when the tank was designed (refer to MEX
203.03). The evaluation must also consider any future corrosion that may take place until the
next T&I. Consideration of any future possible corrosion helps ensure that the tank will be
structurally sound during the entire period of operation until the next T&I.
The possible results of the evaluation can be any one of the following:
The shell may be adequate without restrictions for the required service.
The allowable liquid level may need to be reduced in order to keep the shell
stresses within allowable limits.
When the current shell condition is found to be unacceptable, which option is taken depends
on the extent of repairs that are required, the available time to make the repairs, and the cost
of such repairs.
Actual Thickness Determination
Ultrasonic (UT) measuring devices determine the thickness of the shell over a small area that
is covered by the UT transducer. UT measurements are satisfactory for determining the
overall shell thickness in the area of the transducer, but the transducer area is too large for
satisfactory determination of the shell thickness for pitting types of corrosion. Therefore, a pit
gauge is used to determine the amount of penetration (i.e., depth) in a corrosion pit. A pit
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gauge consists of both a thin shaft that can probe to the bottom of the pit and a mechanism for
"marking" the depth of the probe beyond the general surface of the surrounding material.
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A general UT thickness survey of a tank will typically require a minimum of three readings
on each shell course along vertical lines on the North, East, South, and West sides of the tank.
Additional readings are taken in areas of the shell that have pitting corrosion or in other areas
that obviously have extensive corrosion. For the corroded areas, the thickness readings are
taken by means of a grid pattern that is placed over the area in order to permit detailed
evaluation. The amount of inspection can be increased further, if appropriate, based on the
initial evaluation results.
The minimum thicknesses that are found from the UT survey may be used directly in the shell
integrity assessment. As long as use of the minimum thicknesses does not result in the need
for either repairs or a fill height restriction, there is no incentive to inspect or evaluate the
shell further. However, API-653 permits a less conservative but technically acceptable
approach to determine the thickness that is used in the shell integrity assessment.
For shells that have large, generally corroded areas, the measured thicknesses may be
"averaged" in order to arrive at an overall strength of the shell to use in the integrity
assessment. The basic concept that is employed here is that thicker areas in a corroded region
serve to reinforce areas that are more corroded. An analogy is the use of excess metal that is
available in a pipe or pressure vessel shell as reinforcement of a branch connection. Work
Aid 1 contains the procedure that is used to perform this thickness averaging.
API-653 also permits pitted areas to be completely ignored if the pits can be considered as
"widely scattered," based on their depth and spacing. Work Aid 1 contains the criteria that
must be satisfied for pits to be considered "widely scattered." The rationale here is that as
long as the pit depth and spacing are within the stated limits, they will not decrease the
structural integrity of the tank shell. If the pits cannot be considered "widely scattered," they
must be evaluated as general corrosion.
Minimum Thickness Calculation for Welded Tank Shell
Once the actual shell thicknesses have been determined, they must be compared to the
minimum required thicknesses in order to determine if the actual shell thicknesses are
acceptable. Work Aid 1 contains the procedure for calculating the minimum required
thicknesses. The following paragraphs highlight several considerations with respect to this
procedure.
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API-653 still permits evaluation of a tank shell even if the material is unknown.
However, in the case of unknown material, API-653 requires an allowable
stress that corresponds to a relatively weak carbon steel. Thus, if there is no
documentation that a stronger material was actually used, a significant fill
height restriction might be required even if there has been no corrosion.
The original weld joint efficiency must be used in the thickness calculation
procedure. However, if the original weld joint efficiency is unknown, a very
low weld joint efficiency of 0.7 must be used. Here again, use of this low weld
joint efficiency could result in a significant fill height restriction even without
corrosion.
API-653 permits making a distinction between areas that are near welds and
those areas that are away from welds with regard to the use of weld joint
efficiency in the shell evaluation. A weld joint efficiency of 1.0 may be used
when evaluating corroded areas that are far enough away from welds.
Therefore, use of the original joint efficiency (or 0.7 if unknown) when
evaluating corroded areas that are located away from welds is too conservative
and not required. If use of the weld joint efficiency is a significant factor for a
particular tank, additional inspection data that locates corroded regions with
respect to tank shell welds could be helpful.
The specific gravity of the stored liquid is used in the thickness calculation. If
it is anticipated that the tank might have to be hydrotested in the future due to
repairs or alterations, a specific gravity of 1.0 should be used. It is possible that
there could be no fill height restriction for the normally stored liquid but that
there could be a fill height restriction for the hydrotest water, because of
corroded areas in the shell.
If the relatively simple hand calculation procedures that are contained in API653 find that the tank is unacceptable, API-653 permits the use of the "design
by analysis" approach that is contained in Section VIII, Division 2, Appendix 4
of the ASME Code. This approach requires detailed computer calculations and
more thickness inspection measurements to accurately model the corrosion as
well as to categorize and to evaluate the stresses. However, a tank that is found
to be unacceptable by the simple procedures is often found to be acceptable
when the Division 2 procedures are used.
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As shown in Figure 7, two shell plate attachment details were used in riveted shell
construction. In one detail, the shell plates are lapped over each other and riveted together.
In the second detail, the shell plates are brought close to each other, butt straps are placed
both inside and outside of the shell such that the shell plates are located between the butt
straps, and the assembly is riveted together. The butt-strap design is the stronger of the two.
In each case, the size and spacing of the rivets and the number of rivet rows were determined
during detailed engineering based on the required design loads.
The shell thickness for riveted tanks is evaluated through use of the same minimum thickness
formula that is used for welded shell construction with the following exceptions:
S = 145 MPa (21 000 psi)
E = 1.0 for shell plate that is 150 mm (6 in.) or more away from rivets
Table 2-1 of API-653 provides rivet joint efficiencies that may be used for locations that are
within 150 mm (6 in.) of rivets. These rivet joint efficiencies are based on both whether the
joint is a lap or butt type and the number of rivet rows that are used to connect the plates.
These joint efficiencies are recognized as being conservative; therefore, as an alternative,
API-653 also permits the use of calculated rivet joint efficiencies. Alternate allowable
stresses that are specified in API-653 must be used if calculated rivet joint efficiencies are
used.
CSD should be consulted if repairs are required to a riveted storage tank for two reasons:
A riveted tank will be old, and the shell plate material will not meet current
fracture toughness requirements. Therefore, the design details and installation
procedures that are used for any welded repairs or alterations must be carefully
reviewed to ensure that they do not increase the risk of brittle fracture.
The heat of welding causes differential thermal expansion, which often leads to
the loosening of riveted joints and leakage from the shell. Therefore, repair and
alteration alternatives must be considered in order to select the alternative with
the least probability of causing or increasing a leakage problem.
Wind-induced buckling
Seismic loads
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External loads that are caused by piping; attached equipment such as mixers;
hold down lugs; etc.
Engineering judgment is required to determine the extent to which any of these loads are
considered in the evaluation. CSD should be consulted as needed for assessment of these
other loads.
Minor Defects in Shell Material
A minor defect in the shell material may be defined by one of the following criteria:
The defect repair that is required may be done with weld overlay. This amount
of required repair implies that the defect is small.
Work Aid 1 defines criteria for when repairs must be done and requirements that must be met
for the repairs themselves.
Typical situations that may be considered minor shell defects includes the following:
Isolated pits
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The need to repair minor defects such as those listed above, is determined on an individual
basis. If the defects are located in areas of the shell where the plate thickness exceeds the
thickness required by the design conditions, grinding the defects to a smooth contour without
further repair is permissible. This grinding is done in order to minimize localized stress
concentration effects that are due to any abrupt geometric changes that are associated with the
defect. In situations where grinding thins the plate to an unacceptable level (i.e., thinner than
is required to resist the design loads), weld metal must be added to repair the defect. A
qualified weld procedure must be used for any welding that is done.
Major Defects in Shell Material
Major defects in shell material are those defects that would require the use of replacement
insert plates that are more than 300 mm (12 in.) on a side in order to restore the tank to the
required structural integrity. The most common situation where this amount of repair is
required is if there is extensive general corrosion or severe pitting. Other possible major shell
defects include excessive shell distortions or laminations. Work Aid 1 defines criteria for
when repairs must be done as well as criteria for the repairs themselves.
The guiding philosophy that is used to determine specific repair requirements is that the
repairs must restore tank integrity, the repairs themselves must not make the existing tank
integrity worse, and current API-650 requirements must be met to as great an extent possible
in making the repairs. The paragraphs that follow highlight several of the primary
requirements regarding the repair of major shell defects.
The replacement plate material, welding and welder qualifications, and welding
consumables must meet current API-650 requirements. These requirements
ensure that all new components and welding have the same integrity as in
current new tank construction. The primary concern is to not increase the risk
of experiencing a brittle fracture as a result of the repairs that are done.
Square or rectangular replacement plates must have rounded corners rather than
sharp corners. Rounded corners reduce local stress concentration effects, and
residual welding stresses, and thus they make it less likely that cracks would
initiate at the plate corners when the tank is placed back into service.
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Minimum distances are specified between the new replacement plate welds and
the existing welds that are in the shell. Acceptable distances between welds are
based on shell plate thicknesses, and different distances are specified for each
type of shell weld (i.e., vertical, horizontal, shell-to-bottom, or radial bottom
plate welds). The intent of these minimum distances is to minimize the effect
that shrinkage stresses from the new welds have on existing tank welds.
What type of defect is it? For example, the defect may be a crack, corrosion,
undercut, lack of fusion, or other weld imperfection. The type of defect
influences whether it needs to be repaired and how the repair should be done.
Is the defect from the original construction or did it occur during tank
operation? For example, a lack of penetration or weld undercut is an original
fabrication defect. A crack could be an original fabrication defect as well.
However, a crack could also be caused by excessive local loads, such as loads
from a piping system or excessive settlement.
How extensive is the defect and where is it? For example, cracks will almost
always require repair, especially if they occur at the shell-to-bottom weld.
However, a corroded weld may not need to be repaired as long as the weld is
thick enough for the imposed loads. Less than full penetration at a weld may
also not require repair if the weld is at a high enough elevation in the tank shell
such that the actual weld thickness is sufficient for the imposed loads.
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The existing shell course thicknesses must be evaluated for acceptability based
on the increased design liquid level in the tank that the higher shell permits.
Some shell height increase might be possible in situations where there has not
been significant corrosion or where the originally supplied plate thicknesses
exceeded those that were required. However, from a practical standpoint, it
would be unusual if much more than a 10-15% height increase was possible.
The increased shell height would effect the tank design for wind and seismic
loads. A higher shell for a floating roof tank makes the shell more prone to
wind-induced buckling. Therefore, the existing wind girder design must be
checked. A higher shell also increases the maximum tank overturning moment
due to wind or maximum seismic loads.
All design and installation details must meet the same requirements as for the
repair of major shell defects. These details were previously discussed.
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The specified minimum tensile strength for the shell steel is 60 000 psi.
The specified minimum yield strength for the shell steel is 35 000 psi.
An ultrasonic thickness inspection was made of the shell during a T&I. The following
deterioration was found and was noted in the Inspection and History Report that was
prepared:
There is an area of almost uniform corrosion in the bottom shell course. The
thickness readings in this area along the critical plane are: 0.75 in., 0.70 in.,
0.68 in., 0.75 in., and 0.73 in. The bottom of the critical plane begins at an
elevation of 5 ft. above the bottom of the tank. The thickness readings were
made along a length of 28 in.
A single deep pit is located in the third shell course and is 4 ft. below the top of
the course. The pit measures 0.5 in. deep and is approximately 0.5 in. in
diameter. There is no general corrosion in the area of the pit.
You must determine if any repairs are required to the tank shell in order to maintain the same
design liquid fill height. The following additional information is provided:
Assume that only the stored liquid needs to be considered in this evaluation
(i.e., no other loads) and that there will be no change in service.
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Solution
Work Aid 1 is used to solve this problem.
(100)(0.68)
= 30.5 in.
Therefore, the maximum permitted value of L is 30.5 in. Because the measurements
were made along a shell length of 28 in., this measurement length is acceptable.
Determine the minimum average thickness, t1, along the critical plane.
t1 =
t1 = 0.722 in.
Determine the allowable stress to use. Because this is the bottom course:
0.8Y = 0.8 x 35 000 = 28 000 psi
0.426T = 0.426 x 60 000 = 25 560 psi
Therefore, S = 25 560 psi
Determine the minimum required thickness at the lowest elevation of the corroded
region, tmin.
t min =
2.6D(H 1)G
SE
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Because the bottom of the critical plane is 5 ft. above the tank bottom, H = (61-5) = 56
ft.
t min =
= 0.56 in.
The t1 value of 0.722 in. is greater than the tmin value of 0.56 in. Therefore, the shell
has adequate thickness in this corroded area today. But what about future corrosion in
the next 10 years until the next T&I?
Corrosion Rate
(0. 75 0.68)
15
CA / remaining
CorrosionRate
0.162
0.00467
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= 0.367 in.
0.5
= 0. 0333 in. /year
The pitting rate was 15
Pitting Allowance = 0.0333 x 10 = 0.333 in.
The remaining shell thickness at the bottom of the pit, tpit, is (0.625 - 0.5) = 0.125 in.
Determine the required thickness at the bottom of the pit.
0.5t min + (Pitting Allowance) = 0. 5 0. 367 + 0.333 = 0.5165 in.
Because the required shell thickness, 0.5165 in., is greater than tpit, the pitted area of
the shell must be repaired. There is no reason to also check the pit using the "half
remaining life" criterion because the pitted area has already failed the first evaluation
criterion. Because there is only one isolated pit, a weld overlay repair is sufficient. A
qualified weld procedure and welder must be used to make this repair.
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Requirements that are associated with shell penetrations on existing tanks are contained in
Work Aid 1. The paragraphs that follow discuss several of these requirements.
New Items or Replacement Items
A new shell penetration (or nozzle) may be required due to a change in tank service, to add a
new feature that requires a nozzle, or to replace a deteriorated nozzle. The following are
several examples of when a new shell penetration is required:
The tank service may change to one that requires heated storage rather than
ambient temperature storage. In this case, nozzles are required to add either
heaters or steam circulation pipes.
A hydrostatic tank gauging system may be required. In this case, new nozzles
are required to permit installation of the gauging instruments.
A new or replacement shell penetration will typically be added during a T&I. Penetrations
may also be added by hot tapping, if they are not flush type connections, as long as the
requirements and restrictions on hot tapping that were discussed earlier are met. However,
hot tapping shell penetrations should always be considered as a last resort and only if there are
significant economic incentives to hot tap.
In all cases, new or replacement shell penetrations must either meet API-650 or API-653
requirements. This requirement ensures that the new penetration itself meets current integrity
requirements and will not adversely affect the structural integrity of the existing tank shell and
associated shell welds. It is especially important to meet the requirements for minimum
distance between new and existing welds and to meet the nozzle reinforcement requirements.
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It may be necessary to add a new tank bottom above the existing bottom, and
existing nozzles that are located in the bottom course might need to be raised to
permit this addition.
In each case, it is preferable that the modified shell penetrations meet current API-650
requirements. These requirements include the minimum reinforcement area and the minimum
permitted spacing between adjacent welds. However, Saudi Aramcos normal practice is not
to mandate that shell penetrations be elevated in order to meet API-650 reinforcement and
elevation requirements. Instead, CSD has analyzed each case in order to ensure safe design
and operation while at the same time being cost effective.
Figures 9 and 10 show conceptual details for the addition of a new reinforcing plate to an
existing nozzle. In each case, the new reinforcing plate must be split into two pieces in order
to fit over the neck of the existing nozzle, and the plate is then fillet welded to the tank shell
and nozzle neck. Each reinforcing plate piece is drilled with a telltale hole that permits
pressure testing the reinforcing plate welds.
The detail that is shown in Figure 9 is acceptable as long as the distance between the
reinforcing plate weld to the shell and the shell-to-bottom weld does not violate the API-650
minimum spacing requirements between adjacent welds. The "tombstone type" reinforcement
that is shown in Figure 10 is required for nozzles where the reinforcement plate weld to the
shell would be too close to the shell-to-bottom weld. The "tombstone type" reinforcement
plate extends down to the tank bottom (or annular plate) and is welded to both the bottom (or
annular plate) and the shell.
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It may be necessary to add a new bottom above an existing bottom in cases where the existing
bottom has corroded to the extent that repair is not practical. In this case, the new bottom is
installed approximately 100 mm (4 in.) above the existing bottom. When a new bottom is
installed in this manner, the spacing between existing welds around penetrations that are
located in the bottom shell course and the shell-to-bottom weld of the new bottom will
probably not meet API-650 minimum weld spacing requirements. The following three
options are possible if the minimum weld spacing requirements are not met:
The existing reinforcing plate may be trimmed to increase the space between
the welds provided that the modified reinforcement plate detail meets API-650
requirements. The trimming must be done carefully in order not to damage the
shell plate. The attachment weld for the portion of the reinforcement plate that
is removed must also be removed by gouging or grinding.
Most situations cannot be handled in this manner because there will not be
enough reinforcement left after the trimming is done.
The existing reinforcing plate may be completely removed and then a new
reinforcing plate can be added. The conceptual details that are used for this
option are the same as for adding a new reinforcement plate as shown in
Figures 9 and 10. Again, the shell plate must not be damaged and the existing
reinforcement plate welds must be removed.
This option is acceptable as long as the distance between the nozzle centerline
and the new tank bottom is not less than what is required for an API-650 "LowType" nozzle (see Table 3-8 of API-650).
The last option that may be considered is to relocate the existing nozzle to a
higher position on the shell in order to meet the minimum weld spacing
requirements. This relocation is done by cutting the shell section that contains
the nozzle and its reinforcing plate and raising the entire assembly to the
correct elevation. Figure 11 illustrates this option.
As previously noted, Saudi Aramco normally analyzes each situation individually in order to
determine the most cost effective approach to use in each case.
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The existing condition of the storage tank bottom is determined by inspections that are made
during a T&I. The bottom condition is then evaluated using Saudi Aramco and API
requirements to determine if the bottom is acceptable for continued operation. Work Aid 2
contains the procedures and criteria that are used for making these determinations.
Types of Bottom Corrosion
Of all tank components, the bottom is the one that is most likely to suffer corrosion attack to
the extent that significant repairs are required. Corrosion not only affects refinery storage
tanks, but corrosion also affects storage tanks that are in production, terminal, pipeline, and
marketing facilities as well. Both internal and external surfaces (i.e., topside and underside)
of the tank bottom may be subject to corrosion. Successful, economic repair or control of
bottom corrosion depends first on the determination of what type of corrosion is involved.
External Corrosion
External (i.e., underside) bottom corrosion commonly occurs when moisture is present and a
coarse (greater than 19 mm [3/4 in.] size) and poorly meshed aggregate is used in the tank
pad. Figure 12 illustrates the corrosive action that may occur around aggregate. There is a
low oxygen content at the points of contact between the tank bottom and the aggregate,
whereas the adjacent void spaces are relatively oxygen rich. This oxygen difference between
adjacent locations along the bottom establishes an electrochemical potential and results in
pitting-type corrosion, which is known as oxygen concentration cell corrosion.
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The underside of the bottom plates may also experience corrosion if the tank pad materials
contain chemical contaminants that have highly corrosive sulfur compounds. This situation
would occur if chemical wastes or cinders were previously dumped where the tank is erected.
Product that saturates the soil under the tank as a result of previous tank leaks may also cause
external corrosion. This type of corrosion frequently takes the form of a general metal
thinning. The rate of corrosion depends on the corrosivity of the materials that are involved.
Another cause of external tank bottom corrosion is galvanic action. Galvanic action can
occur between double bottoms, between nearby structures and the tank bottom, or between
active and noble areas of the same tank bottom. Stray electric currents may also be a source
of galvanic corrosion, but instances of stray electric current problems are rare.
Internal Corrosion
Internal (i.e., topside) bottom plate corrosion can occur in tanks that store crude oil, distillates,
heating oil, heavy residual fuel oils, asphalts, and other corrosive liquids. Corrosive attack on
the bottom plates is typically initiated by water that is entrained in crude oil that contains salts,
hydrogen sulfide, and carbon dioxide. As the water settles out of the oil, the water reacts with
sulfur compounds and produces an acidic condition. The acidic condition promotes corrosive
attack. Water also can accumulate by condensation from the air, settle down to the bottom,
and contribute to bottom plate corrosion. Water is constantly being added to storage tanks
with each new batch of oil or product that enters the tank.
Gasoline and other nontreated light products do not normally contain acidic impurities, such
as H2S or CO2; therefore, acid-induced corrosion is not a problem in these cases. However,
because of the high solubility of oxygen in these light products, some dissolved oxygen can
migrate to the bottom water layer and induce a small, but overall uniform, corrosion rate of
approximately 0.025 to 0.05 mm/yr. (1 to 2 mil/yr.). The considerable distance from the
vapor space, that is the oxygen supply, to the bottom brine layer limits the oxygen
concentration. The limited oxygen concentration limits the extent of corrosion that can occur.
Pitting-type corrosion may result from concentration cell corrosion that occurs when a surface
deposit (e.g., mill scale) or a crevice exists on the metal surface and creates an area of low
oxygen concentration. The internal side of tank bottoms usually experiences this corrosion
due to deposited wax or other debris. The accelerated pitting that results may occur at rates of
0.5 to 2 mm/yr. (20 to 80 mils/yr.). Sulfate-reducing bacteria may also cause rapid pitting,
with the pits exhibiting shiny metal surfaces. Pitting that is caused by sulfate-reducing
bacteria is much less common than concentration cell corrosion.
In addition, aggressive galvanic pitting corrosion may be caused by the presence of mill scale,
and galvanic "knife edge" corrosion may occur in the vicinity of welds. Galvanic "knife
edge" corrosion can cause severe metal loss, especially if a bottom coating that has been
applied has failed in the area of the weld.
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Work Aid 2 provides the procedures and requirements to follow when the condition of an
existing tank bottom plate must be evaluated. The paragraphs that follow highlight several
aspects of bottom evaluation.
Bottom Thickness Calculation
API-653 permits two alternative methods for quantifying the remaining thickness of a tank
bottom: the deterministic method and the probabilistic method.
Deterministic Method - The deterministic method requires that the remaining bottom
thickness, as calculated by two different equations, be at least equal to the minimum thickness
that is required by API-653. Both equations consider the original bottom plate thickness,
general corrosion, topside and underside pitting (average and maximum), corrosion rate, and
pitting rate. In each case, the equation starts with the original plate thickness, subtracts
thinning that has occurred already, subtracts further thinning that is expected to occur until the
next T&I, and arrives at a remaining bottom plate thickness.
The difference between the two equations is that in one, the average depth of internal pitting
is combined with the maximum depth of underside pitting. The second equation combines the
maximum depth of internal pitting with the average depth of underside pitting. Thus there is a
tacit assumption that the location of the deepest internal pit will never coincide with the
location of the deepest underside pit. This separation between the two deepest pits cannot be
guaranteed, but it is a reasonable assumption to use for overall evaluation purposes. Work
Aid 2 is based on this evaluation approach.
API-653 does not specify the inspection procedures that must be used, nor their extent, to
determine the values that are needed to solve these equations. The inspection details are left
up to the owner.
Probabilistic Method - The probabilistic method is a statistical analysis of the thickness data
that are obtained from inspection measurements. The objective of this method is to predict
the remaining minimum thickness of the bottom based only on sample scanning
measurements, not extensive measurements, and then to determine whether the minimum
thickness will be less than the API-653 minimum acceptable value. The intent of this
approach is to reduce the amount of inspection time that is needed, and to predict the worst
possible condition in the bottom on a statistical basis with a reasonable degree of confidence.
Here again, API-653 does not specify the details that are required to apply this method.
One negative aspect to the probabilistic method is that if it predicts that the tank bottom is too
thin, it does not locate where the thinnest areas are. Thus, if a problem is predicted, a more
extensive inspection of the tank bottom is still required to develop specific repair
requirements.
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How will the maximum and average depth of underside pitting be determined,
inasmuch as the underside is not visible?
-
Statistical analysis approaches have been developed that will predict the
most likely depth of the deepest pit based on a relatively small number
of thickness measurement data points. This is an example of the
probabilistic method.
Sections of floor plate can be cut out to locally examine the underside
condition, but this is a hit or miss approach.
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The scanner qualitatively locates areas that are thinner than the
thickness threshold level setting, and follow-up ultrasonic thickness
measurements are then made to quantify the actual thicknesses. The
key to this approach is that the thickness threshold level must be set so
that significant corrosion and pitting are located without making an
extraordinarily large number of actual thickness measurements.
Will the tank be divided into sections, or even individual plates, for evaluation
purposes, or will the bottom be evaluated as a whole? The extent to which the
bottom is divided will probably be determined based on whether there are
clearly visible areas of severe internal corrosion or pitting. Severe internal
corrosion or pitting might occur in areas near a center sump, or near the tank
periphery where sludge or sediment might accumulate.
Does the tank have an internal lining and/or cathodic protection system
installed? If not, would installation of one and/or the other affect the need for
bottom repair? Note that installation of these features affects the future
corrosion and pitting of the bottom, not what has already occurred.
What is the extent of repair that is needed to make the bottom acceptable? For
example, would repair of several very localized areas of corrosion make the
bottom acceptable?
The annular plate is required for local load distribution, and the stress distribution in this
region of the tank is relatively complex. Therefore, API-653 thickness acceptance criteria are
more conservative for an annular plate than they are for the rest of the tank bottom. The
minimum thickness criteria for annular plates are based on the following factors:
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If the product specific gravity is less than 1.0 and the annular plate was
not required for seismic considerations, its minimum acceptable
thickness is the value that is specified by Table 2-2 of API-653 plus
corrosion allowance. The minimum acceptable annular plate thickness
specified by Table 2-2 is based on the thickness and stress in the first
shell course.
If the thickness acceptance criteria are not met, API-653 permits performance of a detailed
stress analysis in an attempt to confirm the acceptability of a thinner annular plate for the
specific tank. Such an analysis would be based on the ASME Code Section VIII, Division 2.
A Division 2 stress analysis requires calculation of the specific stress types (e.g., membrane,
bending, local, general) and has acceptance criteria based on the type of stress. The analysis
must consider the extent and location of the corrosion, the degree of foundation support, and
the applied loads. A Division 2 analysis might be advantageous if the API-653 acceptance
criteria would require extensive annular plate replacement.
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Weld repairs to cracked bottom plate lap welds or shell-to-bottom fillet weld.
The root cause of weld cracks should be determined so that appropriate
corrective action can be taken.
The specific approach that is used depends on the extent of the deterioration as well as on cost
and time.
Installation of an internal lining or cathodic protection system are other options that may be
considered if general corrosion or pitting corrosion is excessive. However, these options
address the entire bottom rather than just a portion of it, and are actually bottom
enhancements rather than repairs. These two options will be discussed in a later section of
this module.
Any cracks or leaks that are found in bottom plate lap welds or in the shell-to-bottom fillet
weld must be weld repaired. The cause of such cracks should be determined and corrected so
that the cracks do not recur. Weld cracks in these areas are typically caused by settlement,
original weld defects, or undersized welds.
Repairs to corroded and pitted areas of the bottom plate are made using either weld overlay or
lap-welded patch plates. The choice between these two options is based on the depth and size
of the areas that are to be repaired. Weld overlay is used for relatively small and scattered
corroded or pitted areas, and patch plates are used for larger areas.
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Bottom plate repairs are required only to the extent that is necessary to satisfy the API-653
minimum thickness requirements, as described in Work Aid 2. Parameters that form part of
the bottom plate thickness evaluation include:
If the initial evaluation finds that the existing bottom plate thickness is unacceptable, an
iterative approach may be used to determine the extent of repairs that are required based on
their effect on the evaluation parameters. For example:
If general internal corrosion is a problem, determine how much new plate must
be added to decrease the average internal corrosion enough for the remaining
thickness to be acceptable.
API-653 defines the critical zone of a tank bottom as within the annular plate ring, within 300
mm (12 in.) of the shell, or within 300 mm (12 in.) of the inside edge of the annular plate ring.
This region of the bottom is considered to be critical because the stresses that occur there are
complex in nature. These complex stresses are due to both bending of the tank shell caused
by the hydrostatic head and differential shell and/or bottom settlement. Because this area is
critical, no welding, welded-on patch plates, or weld overlays are allowed within the critical
zone except for welding of the following:
If more extensive repairs are required within the critical zone, the bottom plate or annular
plate under the bottom shell course must be cut out and a new plate must be installed. This
plate replacement has less detrimental impact on the local stress distribution than if repairs are
done by localized weld repair or by the patch plate.
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As previously noted, a stress analysis may be used in an attempt to demonstrate that a locally
corroded area of the bottom plate or annular plate near the shell is acceptable without repair.
Stress analysis may be considered as an option if extensive bottom plate replacement or
annular ring replacement would otherwise be required.
When it is necessary to weld a new annular plate or bottom plate to an existing shell plate of
unknown fracture toughness, increased attention must be paid to the weld procedures and
inspection procedures that are used. The weld details and weld procedures must minimize the
risk of brittle fracture.
The following should be considered to help minimize the risk of brittle fracture:
Use an elongated fillet weld shape (illustrated in Figure 14) to reduce the local
stress intensification.
Fillet welds are normally shaped such that their leg lengths are equal. A fillet
weld that has one leg longer than the other leg (e.g., 2:1 or 3:1) has a lower
stress intensification factor, and thus a lower local stress, than an equal-leg
fillet weld. A brittle fracture will normally initiate at a stress intensification
point. Reducing the local stress reduces the brittle fracture risk.
Perform careful inspection and testing of the initial and final welds (e.g., MT
and vacuum box leak test) to help ensure higher weld quality. A brittle fracture
can initiate at a weld defect.
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Any voids in the foundation that are below the old bottom must be filled with
material such as sand, grout, concrete or crushed limestone. The old bottom
will still provide weight support for the tank and its contents, and the old
bottom must be supported by the underlying tank foundation.
A uniform slot is cut in the shell parallel to the tank bottom as shown in Figure
16. The cut edges of the shell are to be ground, and the new bottom or annular
ring plates are passed through this slot and outside the shell. The new plates
are then welded to the bottom shell course. All dimensional, welding details,
and weld spacing requirements must meet API-650 requirements.
From a practical standpoint, the complete slot cannot be made around the entire
shell at once. The shell will typically be cut such that uniformly spaced,
relatively short sections of the shell remain uncut to provide support for the
upper shell. The remaining uncut shell sections are cut after adjacent new
bottom sections are installed.
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The potential for galvanic corrosion should be addressed by removing the old
tank bottom or by the installation of a cathodic protection system (noted in
Figure 16). If the old bottom is left in place, install a liner on it prior to
installing the fill material in order to prevent galvanic coupling between the two
bottoms.
In situations where a new bottom must be installed, it may be worthwhile to
also consider the installation of a secondary containment and leak detection
system as well. In addition to detecting and containing any bottom leaks that
might occur, such a system provides another advantage. API-653 permits the
bottom plate to corrode to a thickness of 1.25 mm (0.05 in.), rather than the
normal 2.5 mm (0.1 in.), when a secondary containment and leak detection
system is installed.
Existing shell penetrations might have to be raised if the elevation of the new
bottom cuts through their reinforcing plates (which will often be the case) or if
the minimum weld space requirements of API-653 are not met. Raising
existing shell penetrations because of a new bottom installation was previously
discussed.
If the tank has a floating roof, the new bottom profile must keep the roof level
when it is resting on its support legs in the down position. This requirement is
identical to what is required for a new tank.
New bearing plates for floating roof support legs and for fixed roof support
columns must be installed. Again, this requirement is no different from the
requirements for a new tank.
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The sections that follow briefly discuss internal linings and cathodic protection systems.
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Internal Lining
A glass-reinforced plastic (GRP) lining is the type that is most commonly used to protect tank
bottoms from internal corrosion. A GRP lining is an effective and economical method for
reinforcing and corrosion-proofing new and deteriorated tank bottoms. This versatile repair
method is adaptable to both welded and riveted construction, and it offers important
advantages over in-kind replacement of corroded steel. These advantages include:
These factors, coupled with the ruggedness and durability of a GRP lining, make this method
an acceptable tank bottom repair and enhancement technique.
GRP lining involves the application of either a glass-reinforced epoxy resin or glassreinforced polyester resin directly over the existing bottom. The term GRP is sometimes used
interchangeably with FRP (fiber reinforced plastic). The reinforcement or filler material may
be any one of the following:
Fiberglas mat, which is similar to cloth, but made from fibers that are
distributed randomly, rather than woven
Glass flakes
Refurbishing a tank bottom by the installation of a GRP lining is the most practical alternative
to installation of new steel bottoms when significant internal corrosion or pitting is a problem.
This alternative should be considered when a tank bottom has corroded and/or pitted to the
point where its minimum remaining thickness is at the API-653 limit, or will reach that limit
before the next T&I, and internal corrosion or internal pitting is a major factor that has caused
that bottom deterioration.
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While a GRP lining is an attractive bottom repair option, it is not appropriate under the
following circumstances:
GRP linings are not suitable in situations where serious structural weakening
due to general corrosion loss has damaged the mechanical integrity of the tank
bottom. Although properly designed and installed GRP linings can have
sufficient structural integrity to "bridge" relatively large diameter holes (50 mm
[2
in.]
to
125
mm
[5 in.] in diameter), GRP linings cannot be expected to replace the steel tank
bottom.
GRP linings must not be used for heated tankage that requires elevated storage
temperatures. The maximum permissible storage temperature limits for linings
that utilize conventional polyesters and epoxies are 60C (140F) and 82C
(180F), respectively. Asphalt and heavy fuel oil storage tanks normally
require storage temperatures that exceed the safe limits of GRP linings.
GRP linings cannot be used in applications where the linings may be subject to
concentrated chemical attack by strong acids or aromatic solvents. However,
the application of a suitable gel coating over the lining would protect the GRP
lining as long as the gel coating that is used is resistant to attack by the stored
liquid. In most conventional refinery tankage where only trace amounts of
acids or aromatic solvents are present, a GRP lining will exhibit good
resistance and may be used.
GRP linings must not be used without first installing new steel reinforcing
plates in critical locations on the tank bottom, such as the bearing plates located
directly below roof support legs. In addition, patch plates must be installed to
repair large holes prior to installing a GRP lining. If a large number of patch
plates is required, installation of a new bottom may become more economical
than GRP lining repairs. In general, holes that are greater than 25 mm (1 in.) in
diameter or areas with clusters of smaller holes should be repaired with 6.35
mm (1/4 in.) thick steel patch plates prior to installing the lining.
While GRP linings are useful for tank bottom repairs, the linings are not
suitable to deter soil-side corrosion. If aggressive soil-side corrosion is a
problem, a cathodic protection system should be installed to supplement the
lining.
SAES-H-101, Aramco Paints and Coatings Systems, provides specifications for acceptable
coating systems, as well as installation and inspection requirements for these coatings.
Saudi Aramco DeskTop Standards
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The tank is 10 years old and has been in the same service for the entire time.
There are four deep internal pits in the tank bottom. There are also a large
number of shallower pits scattered throughout the tank bottom. All the deep
pits are outside the critical zone of the bottom. The data on the pits are as
follows:
-
One pit near the center of the tank has a depth of 0.202 in.
One pit approximately 20 ft. North of the center of the tank has a depth
of 0.119 in.
One pit approximately 30 ft. Southwest of the center of the tank has a
depth of 0.096 in.
One pit approximately 26 ft. Southeast of the center of the tank has a
depth of 0.102 in.
If the four deepest pits were all repaired, the average depth of internal
pitting that will remain is 0.0024 in.
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Evaluate the inspection data for the bottom and determine if any repairs are required. If
repairs are required, determine what should be done.
Solution
Work Aid 2 is used to solve this problem.
The following data are available from the given information:
GCa
0.043 in.
StPa
0.0035 in.
StPm =
0.202 in.
UPa
0.0017 in.
UPm
0.004 in.
GCm =
0.05 in.
Or
10 years
10 years
To
0.35 in.
Calculate the pitting rate and corrosion rate from the data.
StPm 0.202
=
= 0.0202 in. /yr.
N
10
UPm 0.004
UPr =
=
= 0.0004 in./ yr.
N
10
GCm 0. 05
GCr =
=
= 0.005 in. /yr.
N
10
StPr =
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Because both MRT1 and MRT2 are well under the acceptable value of 0.1 in., bottom plate
repairs are required.
In examining the calculations, the two biggest factors that influence the MRT calculations are
the maximum depth of internal pitting and the influence of the maximum internal pitting rate.
If an internal lining is installed, both StPr and GCr would be zero. Determine if installing an
internal lining is enough without other repairs.
MRT1 = 0.350 - 0.043 - 0.0035 - 0.004 - (0 + 0.0004 + 0)10
MRT1 = 0.2955 in.
MRT2 = 0.350 0.043 0.202 0.0017 (0 + 0. 0004 + 0)(10 )
= 0.0993 in.
Because MRT2 is still less than 0.1 in., additional repairs are required, Assume that the four
deepest pits are also repaired by weld overlay. Therefore:
StPm = 0.089 in.
StPa = 0.0024 in.
Recalculate the value of MRT2 with these new values.
MRT2 = 0.350 0.043 0.089 0.0017 (0 + 0. 0004 + 0)(10 )
= 0.2123 in.
MRT2 is now acceptable. Because MRT1 was already acceptable in the prior calculation and
the pit repair reduces the average internal pit depth that remains, MRT1 does not have to be
recalculated.
In summary, the four deepest pits in the tank bottom should be repaired by weld overlay, and
an internal lining should be installed, in order to make the bottom acceptable.
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It may be necessary to place support members across rafters if the roof plate is
badly corroded. In this manner, inspection personnel do not need to step
directly on severely corroded roof plates.
Gas tests should be made before inspection is begun, especially for floating
roofs. Respirators should be worn or be readily available, depending on the
test results.
One man should remain off the roof as a safety watch to get help, if needed.
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Fixed Roofs
Corrosion is the principal cause of deterioration of fixed roofs. Tanks that store "sour" crudes
are especially vulnerable to internal corrosion on the underside of the roof. Tanks that are
located in humid climates and industrial areas may experience rapid external roof corrosion.
Corrosion of fixed roofs is generally due to three phenomena:
Regular inspections can also avert or minimize problems with corroded or distorted support
columns, rafters, girders, plugged pressure-vacuum vents, and defective welds.
Causes and Rates of Internal Corrosion - Corrosion on the underside of fixed roofs results
from the condensation of vapors that are contained in the tank. This type of attack can appear
as general corrosion or pitting corrosion. Internal roof corrosion has only been observed in
tanks that store "sour" crudes or distillates that contain free H2S. The corrosivity on the
underside of a tank roof is generally low in the absence of both air and H2S in the vapor
space. However, internal roof corrosion becomes considerable when both H2S and air are
present in the vapor.
The roofs of tanks in "sour" crude service can have a life of about 2 to 12 years before small
holes may develop from internal corrosion. The long-term corrosion rates correspond to
about
0.5
to
3 mm/yr. (20 - 120 mils/yr.). The corrosion rate is not necessarily a function of the total
sulfur content in the crude, but rather of the concentration of free H2S in the crude oil or
distillate. Cases have been reported where severe vapor space corrosion occurred in tanks
with crude oils having a total sulfur content as low as from 0.02% to 3.0%.
Causes and Rates of External Corrosion - Atmospheric corrosion is common on fixed roofs
but is generally not severe. Tanks that are located near marine environments might
experience substantial metal loss due to atmospheric corrosion caused by chlorides that are
naturally present in their environment.
Corrosion under insulation that is installed on tank roofs presents a more serious problem
because metal loss can be very rapid and severe. Unfortunately, corrosion under insulation
cannot be detected by visual examination or by nondestructive testing methods without
removing insulation. This type of corrosion depends on the penetration of water or water
vapor into the insulation system, and subsequent retention of the water in the insulation. All
common types of insulation, including mineral wool, glass fiber silicates, foam glass block,
polyurethane foam, and phenolic foam block, have been involved in such corrosion.
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Tank design details can aggravate the problem of corrosion under insulation. As an example,
in one roof insulation system design (illustrated in Figure 19) the shell-to-roof junction
included
a
75 mm (3 in.) vertical rim around the junction. This rim retained rainwater that passed
through the aluminum weather jacketing and resulted in severe roof corrosion.
Another prime cause of corrosion is poor maintenance of roof insulation systems. The
organic materials that are used to caulk metal jackets dry out and crack with age. The cracked
caulk permits water ingress if the caulk is not maintained. In addition, metal jackets may not
be sealed properly at openings into the tank when the jacket is installed. Solar radiation can
also degrade the weather barrier or vapor barrier and make the barrier less able to prevent the
entry of water underneath.
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Thickness Measurements - When the tank is in-service, visual checks should be made for
external corrosion of the roof plates. If the tank is insulated, the condition of the insulation
should be checked to the extent possible and include the following areas:
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Atmospheric corrosion on the topside of external floating roofs is common because the
relatively horizontal roof surface tends to collect particulate contamination from the air, and
the rainwater run-off is too slow to effectively remove the contamination. Depressions or
irregularities in the roof surface will retain moisture, and then the moisture can penetrate any
coating that is installed on the roof (e.g., paint) and establish corrosion cells. As the moisture
finally evaporates, its mineral content is left on the roof to further contaminate the surface.
Scale and rust that is scraped from the shell inside surface during roof movement and
subsequently deposited on the roof may also contribute to the corrosion process.
For tanks that are located in marine environments or in locations that use recirculating salt
water cooling towers, rapid atmospheric corrosion of tank roofs can occur. In most other
areas, however, external corrosion of floating roofs is not severe.
Inspection for Roof Corrosion - Visual in-service checks will locate areas of especially
severe corrosion, such as at depressions in the roof surface, areas around roof support sleeves,
near roof drains and vents, and similar locations where water can accumulate. Badly corroded
areas of the roof should be examined for evidence of leaks. The condition of the paint on the
roof will provide a good indication of any potential roof corrosion problem. Tank roofs
generally require more frequent repainting than tank shells because weathering of the paint
system is more severe on the roof due to its exposure to sunlight and the presence of pools of
water.
When the tank is out-of-service, the underside of the roof should be checked for corrosion.
Ultrasonic thickness measurements should then be made to determine the rate of corrosion.
The external face of the pontoon in the region of the liquid level should be inspected for
grooving, pitting, and corrosion because this area is prone to corrosion due to the liquid-vapor
interface. The interior of the pontoons on double deck roofs is another location that should be
inspected for corrosion.
Recommended retirement thicknesses for floating roof deck plates and pontoons are dictated
by structural requirements. Work Aid 3 contains a procedure that may be used to evaluate
corrosion in floating roofs.
Pontoon rim thickness requirements are generally governed by buckling stability or stress
considerations based on the design rainwater load. These considerations are a function of
tank diameter. If corrosion significantly reduces the rim thickness, a buckling and stress
analysis may be required, and CSD should be contacted.
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Has the tank service been changed to one where internal corrosion is a more
significant factor than it was in the previous service?
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External floating roofs of large diameter tanks are sometimes prone to rippling when wind
blows across the deck. Large diameter tank roofs are also prone to pontoon buckling due to
excessive rainwater accumulation on the center deck. The wind rippling can crack the center
deck welds and/or make the roof prone to sinking by rocking the roof to the point where some
stored liquid gets on top of the deck. Pontoon buckling can reduce the roof stability and
flotation capability, and make the roof prone to sinking as well. If these problems are
encountered, it may be necessary to add circumferential stiffening rings to the deck or
pontoon to provide additional stiffening. Floating roof stiffeners are illustrated in Figure 20.
CSD should be consulted in situations like these in order to develop appropriate repair details.
Any repair that will restore the roof to a condition that allows it to perform its function is
acceptable. Such repairs might include replacement or patching of corroded or excessively
deformed deck plates, repairs to corroded or excessively deformed deck plates, or repairs to
corroded or cracked deck plate lap welds.
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Torn seal fabric must be replaced and not repaired. Repaired fabric is more
prone to subsequent tearing than new fabric.
Any seal repairs or replacements must ensure that the required seal-to-shell gap requirements
are met. Meeting the gap requirements is especially important if the replacement seal is
different from the original design. There are variations among different seal designs with
respect to their ability to accommodate the actual roof-to-shell rim space. One or more of the
following options may be required, depending on the situation:
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Replace all or part of the primary seal system, along with possible installation
of a rim extension for a secondary seal.
The roof deck should be visually checked for any accumulation of product.
-
The pontoons should be checked for tightness to confirm that the roof flotation
capability is maintained.
Roof support legs should be checked for corrosion and repaired or replaced as
needed.
The peripheral roof seal should be checked for wear, deterioration caused by
the stored liquid, and adequate contact with the shell. Damaged seals must be
replaced because such seals could permit excessive vapor losses and cause
restrictions in roof travel.
Seals are installed at the floating roof deck around the fixed roof support
columns and around the access ladder that is located between the fixed roof and
the floating roof. These seals should also be inspected for wear, deterioration,
and adequate contact.
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Shell settlement
Bottom settlement
Correcting settlement problems
In spite of all attempts to prevent or minimize settlement during tank foundation design and
construction, tank shell and/or bottom settlement may still occur over a period of time after
the tank has been placed in service. Therefore, shell and bottom settlement must be evaluated
as part of the periodic tank maintenance activity to determine if any corrective action is
required. The types of shell and bottom settlement that may occur must first be understood in
order to make these evaluations. The sections that follow review the principal types of
settlement and describe how they are evaluated.
Shell Settlement
Types
The three types of shell settlement that may occur are as follows:
Uniform
Planar tilt
Differential
Uniform Shell Settlement - Uniform shell settlement and the problems that it may cause are
illustrated in Figure 21. In uniform shell settlement the shell remains level as it settles. This
type of settlement does not introduce significant stresses or distortions in the tank shell or
bottom and does not necessarily require correction. Problems that can be caused by uniform
shell settlement and possible corrective actions are as follows:
Blockage of surface water drainage from the tank pad into the diked area may
result in water retention at the tank shell. Water retention can be corrected by
regrading the tank pit such that water cannot accumulate near the tank. If this
problem is not corrected, it can cause localized tank corrosion in the lower
portion of the bottom course and annular plate and sketch plate area.
Differential settlement between piping supports and the connecting tank nozzle
may cause overstress of the pipe or tank nozzle. This problem is usually
corrected by adjusting the pipe supports.
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Planar Tilt Shell Settlement - Planar tilt shell settlement is when the shell tilts as it settles
and the bottom of the shell remains in a plane. If the shell elevations are plotted on a linear
scale, true planar tilt settlement produces a sine or cosine curve as illustrated in Figure 22. As
the shell tilts, stresses are introduced that tend to change the shape of the shell. The top of the
shell tends to become elliptical. Shell out-of-roundness can be determined by checking top
diameters and floating roof seal clearances around the circumference of the tank. Figure 22
also illustrates the effect that planar tilt settlement can have on a tank. Typical problems that
may be caused by planar tilt are as follows:
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Differential Shell Settlement - Differential shell settlement is when the bottom of the shell is
no longer in either a level or tilted plane. API-653 also refers to differential shell settlement
as out-of-plane deflection. With differential settlement, the shell undergoes different amounts
of settlement at different points around its circumference. This settlement usually does not
damage the tank structure as long as the settlement is minor and there is adequate support
under the shell. The amount of differential settlement is defined as the deviation between the
actual shell settlements and the sine or cosine curve that represents true planar tilt.
A plot that describes differential settlement is shown in Figure 23. The inherent stiffness of
the shell tends to concentrate shell support at the points with the least amount of settlement.
As with planar tilt settlement, the top of the shell tends to become elliptical. Differential
settlement can cause the same problems as planar tilt settlement. In addition, differential
settlement may cause the shell to buckle or cause the shell-to-bottom area to become
overstressed. Figure 24 illustrates the potential problems that may result from differential
shell settlement.
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Evaluation
32-SAMSS-005 requires that shell settlement measurements be made before, during, and after
hydrostatic testing of newly constructed tanks. The purpose of these measurements is to
determine if the settlement that occurs during the initial filling of the tank is within acceptable
limits. Shell elevation measurements will then be made periodically during the life of the tank
to determine if any unexpectedly large settlements occur. The interval between elevation
measurements is determined based on the results of these measurements. If no settlement
problems are indicated, elevation measurements will typically be made during each T&I.
Shorter settlement measurement intervals are used if initial measurements indicate that there
might be settlement problems. Tank elevation measurements will not disrupt operations
because the measurements can be made with the tank in service.
The shell settlement readings are made relative to the elevation of a permanent bench mark
(See Figure 25). The bench mark must be installed in such a manner that it will not be
affected by future ground settlement due to the tankage. This permanent bench mark permits
an accurate measurement of tank shell settlement over a period of years.
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Reference points are established on the tank shell by welding nuts or similar steel objects to
the tank shell. The reference points are located 100 mm (4 in.) above the bottom edge of the
bottom shell course at equal distances around the circumference of the tank. One reference
point is located at the catch basin. The minimum number of reference points depends upon
the diameter of the tank. API-653 requires that at least 8 reference points be used, and that
the reference points be spaced no more than 9.1 m (30 ft.) apart.
The elevation measuring instrument should be set up at least 1-1/2 tank diameters away from
the tank shell. The elevation readings should be accurate to within 2 mm (1/16 in.).
Appendix B of API-653 contains a basis that may be used for the evaluation of differential
shell settlement (i.e., out-of-plane deflection). The API-653 evaluation basis is contained in
Work Aid 4 and is based on the following parameters:
Tank height
In order to use the API-653 basis, the shell elevation measurements that are made must first
be converted to out-of-plane deflections around the tank circumference. This data conversion
is typically done using a computer program and subtracts the uniform and planar tilt
settlement components from the total settlement measurements.
If the measured differential shell settlement exceeds the API-653 acceptance basis, CSD
should be contacted before any action is taken to relevel the tank. Further evaluations are
typically made to determine if the settlement has caused any damage or operational problems
to the tank. Experience has shown that excessive differential shell settlement will typically
cause shell distortion before any failure will occur. A detailed stress analysis may also be
done to help make a decision. Releveling a tank can be expensive and could cause more
problems than it solves if it is not done properly.
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Bottom Settlement
Types
The three types of bottom settlement that may occur are as follows:
Localized
Center-to-edge
Localized Bottom Settlement - Localized depressions in the tank bottom are normally due to
a soft spot or void in the foundation. Voids in the foundation may occur when settlement has
occurred and the tank has been jacked for repairs. After the jacking operation, the foundation
must be refilled with a grout material to fill in the vacant spaces. However, no technique can
guarantee that the vacant spaces are entirely refilled. Therefore, after jacking operations, it is
not unusual for voids to exist in the foundation. Tunneling under a tank to inspect bottom
plates, or leakage through a bottom plate that softens or disperses pad material, are other
mechanisms that can also cause voids in the foundation.
The bottom plate is not designed to support the tank contents without being uniformly
supported from underneath by the foundation. Therefore, a localized weakness in the
foundation soil can cause overstress in the bottom plates and result in a bottom plate weld
failure. If the foundation in the area of the weld failure is unstable or poorly drained, the
resulting leak can wash out a considerable portion of the foundation and lead to a major tank
bottom failure. Figure 26 illustrates localized bottom settlements that may result from soft
spots or voids in the foundation.
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On tanks that are less than about 50 m (150 ft.) in diameter, excessive bottom settlement is
likely to buckle the shell. On tanks that are over about 50 m (150 ft.) in diameter, frictional
drag is a bigger factor and excessive settlement is more likely to overstress the bottom plates
before noticeable shell buckling occurs.
In tanks that are built on poor foundations, the failure of a bottom weld can lead to
catastrophic foundation washout. However, if the tank foundation was preloaded and
complies with Saudi Aramco design requirements, center-to-edge settlement should not be a
problem.
Combined Bottom and Shell Settlement - Bottom settlement will normally occur in
combination with one or more types of shell settlement. Differential settlement of the shell of
a large diameter tank relative to its bottom can result in significant radial pull on the bottom
plates by the shell. This type of settlement is illustrated in Figure 28. The difference in
settlement between the shell and bottom must be absorbed over a very short distance in the
bottom plates at the tank edge. The resulting excessive distortion of the bottom plates, that
must accommodate all of the stretching, may crack a bottom fillet weld in the distorted region.
The cracked fillet weld could lead to a failure of the bottom.
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Evaluation
Although excessive bottom settlement occurs less frequently than shell settlement, bottom
settlement can result in greater damage and much higher releveling costs. At the same time, it
is more difficult to determine bottom plate settlement patterns while the tank is under
hydrotest or in service.
Because of the greater risks associated with bottom settlement, bottom elevation patterns are
sometimes monitored while the tank is in service in locations where sub-soil conditions are
doubtful or unsatisfactory. In these situations, important data points can be checked by
dropping a sounding line through roof openings, such as manholes and support leg openings,
before and during hydrotest and while the tank is in service. Warped roof plates in a cone
roof tank are a strong indication that excessive bottom settlement may have occurred. In
addition, excessive shell settlement indicates a strong possibility of excessive bottom
settlement as well.
In most situations, bottom elevation measurements to determine settlement patterns will only
be made when the tank is taken out of service for a T&I. API-653 contains recommended
locations for bottom settlement measurements, as shown in Figure 29. Closer measurement
spacing
(75 - 150 mm [3 - 6 in.] apart) should be used in areas where the bottom elevation changes
rapidly, especially close to the shell.
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Appendix B of API-653 contains a basis that may be used for the evaluation of tank bottom
settlement. This basis is included in Work Aid 4. The API-653 criteria is based on the
following parameters:
Depth of depression (or the height of the bulge) in the tank bottom. Note that
local areas of the bottom may be bulged up rather than depressed down.
Bulges are evaluated using the same basis as depressions.
Radius of the largest circle that may be inscribed within the depressed (or
bulged) area.
An assumption that the bottom plate lap welds are made with a single weld
pass.
If the measured bottom plate settlement exceeds the API-653 acceptance basis, CSD should
be contacted before any action is taken to repair or relevel the bottom. The API-653
evaluation basis is relatively conservative, and it may be worthwhile to do a detailed stress
analysis to determine the actual situation if extensive repair or releveling is required. The
API-653 basis is especially conservative if the bottom plate lap welds are made with two or
more weld passes rather than the one pass that API-653 assumes.
Methods for Correcting Settlement Problems
If the shell or bottom settlement is excessive, corrective action must be taken before
unacceptable damage and tank leakage occurs. Because significant time is required to
properly plan, evaluate, and execute settlement corrections, the decision to relevel cannot be
taken lightly. Improper releveling can cause as much or more damage to the tank than the
settlement that it is meant to correct. The paragraphs that follow describe the primary
considerations and techniques for correcting shell and bottom settlement.
Shell Releveling Considerations and Techniques
Considerations - Three forms of shell releveling may be considered: releveling only a part of
the shell, releveling the entire shell, or releveling both the entire shell and the tank bottom as
well. The extent of releveling should be minimized consistent with fixing current problems
and minimizing the probability of needing future releveling.
In many cases, releveling only part of the shell is necessary. In these cases, the low points of
the shell are jacked by amounts that range from 50 mm (2 in.) to 175 mm (7 in.). In addition,
when the entire shell must be releveled and settlement is expected to continue, local
overjacking of the shell in areas of poor soil may be desirable. When overjacking is
specified, it should be done so that the resulting radial displacements of the shell will not
cause floating roof binding or gaps between the floating roof and shell. Calculation
procedures are available that predict the amount of radial shell displacement for specified
changes in shell elevation.
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Techniques - The most common technique for releveling a tank shell is to lift the shell with
hydraulic jacks and pack selected materials beneath the bottom and annular plates. Two
basically different procedures for tank jacking are widely employed: jacking against the tank
shell and jacking from beneath the bottom or annular plates.
When jacking against the tank shell, jacking lugs or brackets are welded to the tank shell
around its periphery as close to the bottom or annular plate as possible. Figure 30 illustrates
the details for typical jacking lugs. A compact hydraulic jack (or a pair of jacks) is placed on
a timber footing at each bracket location, and the tank is gradually lifted to a height that is
equal to the jack stroke (generally 100 mm [4 in.]). Timber beams or steel shims are then
used to temporarily support the tank shell while the jack is released, and additional timber
beams are placed between the jack and the foundation. The entire process is repeated until
the tank shell is level and at the required elevation.
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Depending on the jacking system, the jack spacing, and the shell thickness, externally
mounted jacks can impose significant stresses on the tank shell. Therefore, it is important that
the shell stresses be checked and any necessary strengthening measures carried out before
jacking is begun.
The major advantage of jacking against the shell when compared to jacking from beneath the
bottom or annular plates is that disturbance to the existing foundation is minimal. Because
the jacks are not beneath the shell, placement and compaction of select backfill is more
uniform and results in less potential for differential shell settlement in the future.
The disadvantage of jacking against the shell when compared to jacking from beneath the
annular plates is the welding that is required to attach the brackets to the shell and to provide
any necessary shell reinforcement. This welding can also build up residual stresses in the
shell and possibly cause brittle fracture, particularly in older tanks where steels with poor
fracture toughness were often used. On newer tanks that are constructed of high strength
steel, the weldability of the bracket to the shell may be a problem.
There are at least two methods for jacking from beneath the bottom or annular plates: using a
jacking frame, or excavating pits for the placement of hydraulic jacks.
The preferred method for jacking from beneath the bottom annular plates is to use a jacking
frame. A typical jacking frame is illustrated in Figure 31. The frame is equipped with slender
jacking shoes that are shaped so that they can be easily slipped beneath the tank shell. The
frames are spaced every 3 to 4.5 m (10 to 15 ft.) around the tank periphery. The tank can be
jacked to a maximum height of 300 mm (12 in.) with this method. No welding to the tank
shell is required, and the jacking frames are reusable. Due to the size and shape of the jacking
shoe, there is little disturbance to the existing foundation. The disadvantages of this method
are the initial fabrication cost of the frames and the limited jacking height of 300 mm (12 in.).
The frames also cannot be used to lift and relevel the entire tank bottom; therefore, this
method cannot be used for all tank releveling needs.
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All tank elevation changes should be gradual to minimize stresses in the overall
tank structure.
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Some overjacking may be done when further settlement can be anticipated and
predicted.
Steel bearing plates under the jacks spread the jacking reaction and minimize
the risk that jacks may be tipped over or kicked out.
During jacking operations, careful attention must be paid to the bottom plates,
especially on floating roof tanks. When the shell is raised to a certain point, the
shell begins to lift the bottom plates at the first row of roof support legs. If the
shell has to be raised further, it will be necessary to release the loads from these
legs with temporary roof supports. Removing the load from these legs is
accomplished by welding temporary brackets to the inside of the shell to
support the outer periphery of the pontoon.
If local areas of the bottom are depressed, pump Portland cement grout
underneath the affected area through a hole in the tank bottom.
Lift the entire tank and relevel the affected area. Coarse sand or gravel should
be used as the filler material.
Remove the bottom plates in the affected area, relevel, and replace the plates.
When releveling, coarse sand or gravel should be used as the filler material.
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Add a second pass to the bottom plate fillet welds in the affected area. Prior to
adding the second pass, the original fillet welds must be sand blasted and
cleaned to ensure that the fillet welds are free of all scale and oil.
Techniques - The tank bottom may be releveled by pressure grouting, jacking, or other less
commonly used methods. Selection among any of these releveling techniques, or a
combination of them, should be based on an economic evaluation.
Pressure grouting of tank bottoms is appropriate for correcting settlement in localized areas of
the bottom plates. In this technique, grout is injected under pressure between the bottom plate
and the foundation pad, not directly into the pad. Pressure grouting has proven to be
successful at many installations. A wide variety of grout mixes are offered by contractor
specialists. All of these mixes include various materials and additives that improve
pumpability and flow characteristics. For tank bottom releveling, a low compressive strength
is a desirable characteristic of the grout, because a low compressive strength minimizes hard
spots that might damage the bottom plates should further settlement occur.
Pressure grouting is generally not economical for releveling a large portion of a tank bottom.
For tanks that require more than local releveling, it is usually more economical to lift the
entire tank off its foundation and relevel and reshape the entire pad. When this technique is
used, the entire tank is jacked up and cribbed to a height that provides headroom for
motorized dumpers and small bulldozers. Mechanical equipment is then used to relevel and
reshape the entire foundation with sand, gravel, and crushed stone. The tank is again jacked
clear, cribbing removed, and jacks released to set the tank back on the new pad. This
technique has proven to be successful on numerous tanks for correcting extensive bottom
settlements.
Three other techniques can also be considered for bottom releveling:
Float the tank on water or air, move the tank to an adjacent temporary site,
repair the original foundation, and refloat the tank back onto the repaired
foundation.
Lift the tank, slide the tank off its foundation using a rail system, and then
return the tank to the foundation after repairs are made.
Remove the tank bottom plates, reshape the foundation, and install new bottom
plates.
All of these techniques have been successfully used. The choice of the specific technique to
use depends on factors such as cost, the extent of required repairs, the size and type of tank,
and the experience of the contractor who is engaged to perform the work.
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Sample Problem 3: Determine the Need for Corrective Action Based on Tank Settlement
Measurements
Shell settlement measurements were made of a 100 ft. diameter floating roof tank. The shell
elevation measurements that were noted in the Inspection and History Report have been
converted to out-of-plane deflections, and these deflections are shown in Figure 33. The
following information is also available:
The Modulus of Elasticity of the shell plate material is 29 500 000 psi.
0.01
30
0.06
60
-0.02
90
0.02
120
-0.02
150
0.02
180
0.01
210
0.02
240
-0.02
10
270
0.01
11
300
-0.02
12
330
-0.01
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Solution
Work Aid 4 is used to solve this problem.
There are more than the minimum required number of settlement measurement points. Now,
confirm that the settlement measurements were not made too far apart.
D
N
(100 )
L=
= 26. 2 ft.
12
L=
Because this is less than 30 ft., the spacing between the measurements is acceptable.
Now determine the maximum permitted out-of-plane deflection.
S=
S=
11 L2 Y
2EH
11 26 . 2 2 38 000
2 29 500 000 51
S = 0.095 ft . = 1. 14 in .
Because the maximum measured out-of-plane deflection is only 0.06 in. and is less than the
permitted value of 1.14 in., no action is required.
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General Requirements
Para. 3.0
Test Preparation
Para. 4.0
Tanks
Para. 6.6
A reconstructed tank
Any tank that has undergone "major repairs" or "major alterations," unless the
tank meets specific exemption requirements that are stated in API-653
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Installation of any shell opening that is larger than 300 mm (12 in.) nominal
size and is located below the design liquid level.
Installation of any opening into the bottom that is located within 300 mm (12
in.) of the shell.
Removal and replacement or addition of any shell plate that is located below
the design liquid level, or any annular plate ring material, where the longest
dimension of the replacement plate exceeds 300 mm (12 in.).
Complete or partial (over half of the weld thickness) removal and replacement
of more than 300 mm (12 in.) of vertical shell plate weld or radial weld that
joins annular plate sections.
Re-hydrotesting an existing tank costs additional time and money. Re-hydrotesting also
frequently causes problems with regard to water disposal if the hydrotest water becomes
contaminated with remnants of the tank contents. Therefore, Para. 10.3.2 of API-653
indicates that re-hydrotesting after major repairs or alterations is not required, provided that
specific exemption criteria are met. The exemption criteria are based on the following
factors:
The intent of the re-hydrotest exemption criteria is to identify situations where the repairs or
alterations that are done are not likely to increase the risk of a brittle fracture in the tank. A
re-hydrotest is not required for these low-risk situations. Participants are referred to API-653
for the specific exemption requirements.
SAES-D-108 adds to the API-653 re-hydrotest requirements. Para. 10.3.1 specifies that the
maximum tank shell stress during the re-hydrotest must be limited to 90% of the specified
minimum yield strength of the material. The maximum shell stress must be based on the
actual shell thicknesses that were measured during a shell inspection.
Saudi Aramco DeskTop Standards
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Analyze the inspection data that is available from a T&I and that is documented in an
Inspection and History Report to determine the current condition of the tank shell or
shell penetration, prior inspection and repair history, the extent of the problem (if any),
and any alterations that may be required.
2.
Gather the necessary design information for the tank. This information includes items
such as tank or nozzle diameter and wall thickness, materials, and maximum required
fill height. This information may be obtained from the Contractor Design Package for
the tank.
3.
4.
Compare each potential alternative that was determined in Step 3 with the pertinent
requirements that are contained in SAES-D-108 and API-653 to determine the need
for repair, replacement, or alteration.
5.
Identify the key parameters that will influence the decision for repair, replacement, or
alteration. Parameters that must be considered are as follows:
The time that is available to work and the desired time interval until the next
T&I.
6.
7.
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Are there any distortions in the tank shell, such as out-of-roundness, buckled areas, or
flat spots? Quantify their extent and location.
2.
Are there any flaws, such as cracks or laminations, in the shell base plate material?
Quantify their extent and location.
3.
Have any weld flaws been identified? Weld flaws may include the following:
Cracks
Lack of fusion
Corrosion or pitting
Document the type, the location, and the extent of the weld flaws.
4.
Have any generally corroded or pitted areas been identified? If "Yes," proceed to Step
5. If "No," the inspection data collection for tank shell evaluation is complete.
5.
For generally corroded areas, proceed to Step 6. For pitted areas, proceed to Step 12.
6.
For each generally corroded area, determine the minimum shell thickness, t2, at any
point in the corroded area, excluding widely scattered pits. Refer to Figure 2-1 in the
class reference copies of API-653 in Course Handout 1 (see Figure 34).
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7.
English Units
L = 3. 7 Dt2
t2
If the calculated value of L is greater than 1 m (40 in.), set the value of L to 1 m (40
in.).
8.
Determine which vertical plane(s) in the generally corroded area is likely to be most
affected by corrosion. These vertical planes are the critical planes.
9.
10.
Calculate the average thickness of each critical plane from the thickness measurements
that were made.
11.
Determine the lowest average thickness in the corroded region, t1, as the smallest
average thickness considering all of the critical planes. The data collection required
for the evaluation of generally corroded areas of a tank shell is complete with this step.
12.
distance, L.
the corroded
divided into
section must
Remaining shell thickness at the bottom of the pits, tpit (see Figure 35).
The sum of the pit dimensions along any vertical line that extends across the
pits. Refer to Figure 2-2 in the class reference copy of API-653 in Course
Handout 1 (see Figure 36).
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The data collection that is required for the evaluation of pitted areas of a tank shell is
complete with this step.
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14.
Size of penetration
For the addition of a new shell penetration, obtain the following information:
Thickness and condition of the tank shell in the area where the penetration and
its associated reinforcement will be welded
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12.7 (0.5)
150 (6)
Any reinforcing plate that is to be added to a shell opening must not be added inside
the tank.
2.
Completed repairs to any fillet welds must be examined over their complete length by
means of the Wet Fluorescent Magnetic Particle Method.
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Shell distortion may be considered acceptable if the deviation from uniform curvature
is within both of the following limits:
Contact the Consulting Services Department (CSD) if the distortion exceeds either of
these limits.
2.
Weld cracks shall be removed by gouging or grinding to sound metal. The area must
then be prepared for the weld repair.
3.
Slag, porosity, lack of fusion, laminations, and weld undercut must be evaluated by
inspection personnel in conjunction with CSD, as appropriate. Unacceptable defects
must be removed, and the weld must be repaired.
4.
Arc strikes that are located in or adjacent to welds must be repaired by grinding and/or
welding. Arc strikes that are repaired by welding must be ground flush with the plate
surface.
5.
6.
Grind the defect to a smooth contour with the shell plate surface.
Add weld overlay if the resulting shell thickness after grinding is less than the
minimum acceptable thickness.
The minimum acceptable thickness is
determined as described for the evaluation of generally corroded areas in Step
6.
Using the procedure that follows, evaluate generally corroded areas in the shell.
a.
Determine the specified minimum tensile strength of the shell plate material, T,
MPa (psi). Obtain from the original design data or API-650. If the material is
unknown, use T = 379 MPa (55 000 psi).
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b.
Determine the specified minimum yield strength of the shell plate material, Y,
MPa (psi). Obtain the yield strength from the original design data or API-650.
If the material is unknown, use Y = 207 MPa (30 000 psi).
c.
d.
For the bottom and second course, S is the lower of 0.80Y or 0.426T.
Use the formula that follows to calculate the minimum acceptable thickness for
a welded shell that is no more than 61 m (200 ft.) in diameter. See Step 6g for
larger diameter tanks.
SI Units
t min =
English Units
4. 9D(H 0. 3)
SE
t min =
2.6D(H 1)G
SE
Where:
tmin = Minimum acceptable shell thickness, mm (in.)
S
1.0 if the corroded area is away from welds by at least the greater
of 25 mm (1 in.) or twice the plate thickness
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e.
The generally corroded area is acceptable if both the equations that follow are
satisfied.
t1 tmin + CA
t2 0.6 tmin + CA
Where:
tmin
t1
t2
CA
CA
Maximum CorrosionRate =
f.
As a final check, it must also be confirmed that the T&I interval is no greater
than half of the remaining tank life (based on the general corrosion).
(1)
Using each equation that is in Step 6e, calculate the remaining corrosion
allowance, CA/remaining, mm (in.).
CA/remaining - 1 = tmin - t1
CA/remaining - 2 = 0.6 tmin - t2
CA/remaining = the smaller of CA/remaining - 1 or CA/remaining - 2
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(2)
(3)
g.
CA / remaining
Maximum CorrosionRate
The T&I interval (based on the general corrosion) can be no longer than
half of the Remaining Life.
If the criteria in Step 6e and Step 6f are not satisfied, the following options are
available:
h.
i.
If the shell is riveted rather than welded, refer to Para 2.3.4 of API-653 for
requirements for the calculation of tmin.
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7.
Using the procedure that follows, evaluate pitted areas in the shell.
a.
b.
Widely scattered pits may be ignored if the conditions that follow are met.
The remaining shell thickness at the bottom of the pit, tpit, must satisfy
the following equation:
tpit 0.5 tmin + (Pitting Allowance)
The Pitting Allowance should be determined based on the maximum
pitting rate and the desired interval to the next T&I.
(Pitting Allowance) = (Maximum Pitting Rate) x (Desired T&I Interval)
Maximum Pitting Rate =
It must also be confirmed that the T&I interval is no greater than half
the remaining tank life (based on the pitting).
-
c.
The sum of the pit dimensions along any vertical line that extends
across the pits must not exceed 50 mm (2 in.) in any 200 mm (8 in.)
length
(see Figure 36).
If the pitted area does not satisfy the requirements in Step 7b, the pits cannot be
ignored. The pitted area must then be evaluated as a generally corroded region,
and the procedure contained in Step 6 must be used.
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8.
Evaluate the acceptability of corroded or pitted regions for loads other than the
hydrostatic head, as appropriate. This evaluation would consider loads such as from
connected piping systems, wind, or temperature over 93C (200F). Consult CSD as
appropriate.
9.
Corroded or pitted areas of shell plate that are unacceptable may be repaired by either
weld overlay or by cutting out the corroded section of shell and replacing the removed
section with new material. Use weld overlay only for relatively small corroded areas.
In either case, welding requirements that are contained in Section 9 of API-653 must
be met.
The requirements that follow shall be met when a replacement shell plate is used for
repair.
a.
b.
The minimum plate thickness shall meet the requirements in Para. 7.2.1 of
API-653. The replacement plate thickness will typically equal the thickness of
the plate as originally constructed.
c.
Circular
Oblong
d.
e.
f.
g.
Shell replacement plates shall be welded with butt-welded joints with complete
penetration and complete fusion.
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t 12.7 (0.5)
150 (6)
75 (3)
150 (6)
300 (12)
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11.
For existing shell penetrations, use the available inspection data and take the following
action:
Flaws other than corrosion (such as weld cracks, lack of fusion, gouges) shall
be treated in the same manner as if these flaws were found on the shell. See
Steps 2 through 5.
Evaluate as follows the corroded regions within the nozzle itself, or within its
reinforcement region on the shell:
-
Compare the amount of corrosion that has taken place with the
originally specified corrosion allowance. If no corrosion allowance was
specified, or if the originally specified corrosion allowance has been
exceeded, refer the situation to CSD for review.
All repairs must comply with API-650 requirements. If this repair involves
shell repair also, the requirements that are contained in Step 9 shall be met.
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12.
For new shell penetrations that are added during a T&I, design and installation details
shall meet either API-650 requirements or the requirements that are contained in Para.
7.7.2 of API-653.
13.
For new shell penetrations that are added by hot tapping, design and installation shall
meet SAES-D-108 and API-653 requirements.
14.
Details of the alteration must comply with API-650 requirements, including the
minimum reinforcing area and minimum distance between adjacent welds.
Refer to Para. 7.8.2 of API-653 for alteration requirements that may apply
when a new tank bottom is installed above an existing bottom.
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Refer to Work Aid 1A for general procedural steps that are also applicable to the
evaluation of tank bottoms.
2.
Is there any general internal corrosion? If there is, quantify its extent and location.
3.
Is there any internal pitting? If there is, quantify its depth and location.
4.
Is there any underside pitting? If there is, quantify its depth and location.
5.
Is there an internal bottom lining installed? If yes, determine its thickness and design
details.
6.
7.
Does the tank have a leak detection and secondary containment system installed?
8.
Have any cracks or leaks been identified in the shell-to-bottom weld or in any other
bottom plate welds? If yes, quantify their extent and location.
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Use the following procedure to determine the minimum bottom plate thickness.
a.
b.
c.
2.
If the entire tank bottom must be replaced, the new bottom must be installed above the
original bottom if this is the first time that the bottom is being replaced. Subsequent
bottom replacements must be made at the same elevation as the first replacement
bottom. The existing cushioning material that is located between the existing bottom
and the new bottom must be completely replaced.
3.
Completed repairs to any fillet welds must be examined over their full length by the
Wet Fluorescent Magnetic Particle Method.
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b.
Average depth of internal pitting measured from the original bottom plate
thickness, StPa, mm (in.)
c.
Maximum depth of internal pitting, StPm, mm (in.). Note that the value that is
used for the initial evaluation is based on the inspection data. Subsequent
evaluations may be made based on the maximum internal pit depth that would
still remain after any repairs that are done.
d.
e.
f.
g.
StPm
N
Where:
service
StPr
installed
h.
UPm
N
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i.
GCm
N
GCr
2.
Determine the desired maximum T&I interval for the tank, Or, in years.
3.
Use the following formula to calculate the minimum expected remaining thickness at
the next T&I, based on average internal pitting and maximum underside pitting.
MRT1 = To GCa StP a UPm (StPr + UPr + GCr )Or
Where:
MRT1 =
To
Use the following formula to calculate the minimum expected remaining thickness
until the next T&I, based on maximum internal pitting and average underside pitting:
MRT2 = T o GCa StPm UPa (StPr + UPr + GCr )Or
Where:
MRT2
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5.
The minimum acceptable values of MRT1 and MRT2 are shown in Figure 39
for bottom plates, which are not annular plates.
1.25 (0.05)
1.25 (0.05)
The minimum acceptable values of MRT1 and MRT2 for butt-welded annular
plates shall be in accordance with Para. 2.4.8 of API-653. See Figure 40.
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<27 000
<29 700
<32 400
t 0.75
0.17
0.20
0.23
0.30
0.17
0.22
0.31
0.38
0.17
0.26
0.38
0.48
1.25 t 1.50
0.22
0.34
0.47
0.59
t > 1.50
0.27
0.40
0.53
0.68
Notes:
1.
2.
6.
Are the bottom (and annular plate) thicknesses, MRT1 and MRT2, in accordance with
the acceptance criteria that are contained in Step 5? If both MRT1 and MRT2 meet
these criteria, the tank bottom (or annular plate) thickness is acceptable without further
repair; proceed to Step 8. If one or both of these thicknesses are not acceptable,
proceed
to
Step 7.
7.
If Step 6 has found that the bottom and/or annular plate thickness was not acceptable,
examine the individual terms in the MRT1 and MRT2 equations to determine which
factor(s) needs to be reduced in order to increase the calculated thickness to an
acceptable level. Items that may be considered, alone or in combination, are as
follows:
Install an internal lining that is at least 1.25 mm (0.05 in.) thick and meets API
RP 652, if one is not currently installed. Installation of a lining will reduce StPr
to zero, and it will allow MRT1 and MRT2 to be as low as 1.25 mm (0.05 in.).
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Determining Requirements for Repair or Alteration of Storage Tanks
Weld overlay repair or use lap-welded patch plates to reduce the maximum and
average remaining internal pit depths (StPm and StPa respectively).
The exact approach to take depends on the extent of repairs that are required, the cost,
the available time, and the requirements and limitations that are contained in API-653
with respect to bottom repairs.
8.
If cracks or leaks were found in the shell-to-bottom weld or in the bottom plate lap
welds, these defects shall be weld repaired.
9.
All tank bottom weld repairs must meet the welding requirements that are contained in
Section 9 of API-653.
10.
Portions of a tank bottom may be repaired by weld overlay or lap-welded patch plates
within the following restrictions:
a.
No welding, welded-on patch plates, or weld overlays are permitted within the
critical zone, except for welding of the following:
-
11.
b.
If more extensive repairs are required within the critical zone than the repairs
that are listed in Step 10a, the bottom plate (or annular plate) under the bottom
shell course must be cut out and a new plate must be installed. Weld spacing
requirements must meet Para. 3.1.5.4 and Para. 3.1.5.5 of API-650.
c.
The repair of sumps that are located within the critical zone shall be in
accordance with Step 10b.
If the entire bottom must be replaced, the requirements that are contained in Para.
7.9.2 of API-653 shall be met.
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Refer to Work Aid 1A for general procedural steps that are also applicable to the
evaluation of tank roofs.
2.
Is there any corrosion of roof support structural members on the inside surface of the
roof? If there is, quantify its extent and location.
3.
Is there any external corrosion of the roof surface? If yes, quantify its extent and
location.
4.
Are any roof welds cracked or have other weld defects been identified?
quantify their extent and location.
5.
Has any distortion or other structural damage been noted in any roof support
members? If yes, quantify its extent and location.
If yes,
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Determining Requirements for Repair or Alteration of Storage Tanks
If roof support structural members have corroded, determine if the extent of corrosion
has exceeded the original corrosion allowance or if it will exceed it before the next
T&I. If the corrosion is too much, the structural integrity of the roof support system
must be evaluated. Refer the situation to CSD.
2.
Verify that no portion of the roof plates has corroded to an average thickness that is
less than 2.3 mm (0.09 in.) in any 645 cm2 (100 in.2) area. Using lap-welded patch
plates that are at least 4.8 mm (0.188 in.) thick, repair corroded areas as necessary.
3.
If the roof is a fixed roof, the evaluation is complete. If the roof is a floating roof,
proceed to Step 4.
Floating Roof
4.
Verify that the roof plates and pontoons do not have cracks or punctures. Repair or
replace sections that have cracks or punctures, as needed.
5.
Evaluate areas of the roof that exhibit pitting to determine whether the pitting will
proceed through the roof prior to the next T&I. Repair or replace any areas that are
likely to pit through the roof.
6.
Verify that the roof support systems, perimeter seal systems, and appurtenances (such
as roof rolling ladder, anti-rotation devices, water drain systems, and venting systems)
do not require repair or replacement. Repair or replace, as needed.
7.
If corrosion has occurred in the pontoon rims, contact CSD inasmuch as a stress and/or
buckling analysis may be required. If the rim is less than 2.5 mm (0.1 in.) thick, it
must be replaced with at least 4.8 mm (0.188 in.) thick plate. However, thicker plate
may be necessary, depending on the tank size and the results of the stress and/or
buckling analyses.
8.
If the perimeter seal requires repair or replacement, this shall be done in accordance
with Para. 7.12 of API-653.
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Determining Requirements for Repair or Alteration of Storage Tanks
Refer to Work Aid 1A for general procedural steps that are also applicable to the
evaluation of shell and bottom settlement.
2.
3.
The maximum distance between the measurement points is 9.1 m (30 ft.)
Confirm that the shell elevation measurements have been converted to out-of-plane
deflection readings. This measurement conversion removes the uniform settlement
and rigid body tilt of the tank from consideration in the settlement evaluation.
Reference Figure B-3 of API-653 (see Figure 41).
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Determining Requirements for Repair or Alteration of Storage Tanks
4.
If bottom settlement or bulging has been identified, confirm that the following
information has been obtained:
Radius of the largest circle that can be inscribed within the bulged or depressed
area, R, see Figure 42
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Determining Requirements for Repair or Alteration of Storage Tanks
Confirm that at least 8 evenly spaced shell elevation measurement points were used. If
not, more elevation measurement points are required.
3.
Confirm that the maximum arc length between shell elevation measurement points is
9.1 m (30 ft.). If there is a greater distance between points, more elevation
measurement points are required. The arc length between measurement points may be
calculated as follows:
L=
D
N
Where:
L = Arc length between shell elevation measurement points, m (ft.)
D = Tank diameter, m (ft.)
N = Number of measurement points
4.
11L2 Y
2EH
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Where:
S
English Units
B 30.83R
B 0.37R
Where:
7.
If the bottom of the tank is below grade, appropriate corrective action must be taken in
order to regrade the pit and avoid rainwater accumulation near the tank.
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GLOSSARY
alteration
hot tap
I-T&I interval
Performance Alert
reconstruction
repair
T&I
T&I interval
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