Dp22b (Atmospheric Storage)

OFFSITES SYSTEMS STORAGE FACILITIES DESIGN PRACTICES
ATMOSPHERIC STORAGE Section Page

EXXON XXII-B 1 of 49
ENGINEERING Date
PROPRIETARY INFORMATION - For Authorized Company Use Only December, 1999
Changes shown by ➧
CONTENTS
Section Page
SCOPE ............................................................................................................................................................ 4
REFERENCES ................................................................................................................................................ 4
DESIGN PRACTICES............................................................................................................................. 4
INTERNATIONAL PRACTICES.............................................................................................................. 4
API BULLETINS AND STANDARDS ...................................................................................................... 4
OTHER LITERATURE ............................................................................................................................ 5
DEFINITIONS.................................................................................................................................................. 5
PRINCIPAL TYPES OF ATMOSPHERIC STORAGE TANKS ....................................................................... 5

FIXED ROOF TANKS ............................................................................................................................. 5
GEODESIC DOME ROOFS.................................................................................................................... 6
FLOATING ROOF TANKS...................................................................................................................... 6
SELECTION OF THE TYPE OF ATMOSPHERIC TANK ............................................................................... 7

EXTERNAL FLOATING ROOF TANKS .................................................................................................. 7
INTERNAL FLOATING ROOF TANK...................................................................................................... 7
FIXED ROOF TANKS ............................................................................................................................. 7
BASIC DESIGN CONSIDERATIONS ............................................................................................................. 8

DESIGN VALUES FOR INNAGE AND OUTAGE ................................................................................... 8
ECONOMIC TANK SIZING..................................................................................................................... 8
STRUCTURAL DESIGN CONSIDERATIONS ........................................................................................ 8
TANK HEATING ..................................................................................................................................... 9
TANK MIXERS........................................................................................................................................ 9
LOCAL SITE CONDITIONS.................................................................................................................... 9
TANKAGE REALLOCATION .................................................................................................................. 9
STOCK CLASSIFICATION ..................................................................................................................... 9
ENVIRONMENTAL IMPACT ON TANK BOTTOM DESIGN................................................................. 10
DESIGN PROCEDURES............................................................................................................................... 10
SIZING CRUDE TANKAGE .................................................................................................................. 10
SIZING PRODUCT TANKAGE ............................................................................................................. 11
SIZING COMPONENT TANKAGE........................................................................................................ 11
SIZING INTERMEDIATE TANKAGE .................................................................................................... 12
GROSS TANKAGE VOLUME............................................................................................................... 13
TANK ACCESSORIES.......................................................................................................................... 13
Tank Nozzles ..................................................................................................................................... 13
WATER DRAWOFF EQUIPMENT........................................................................................................ 14
TEMPERATURE INSTRUMENTS ........................................................................................................ 16
TANK MIXING EQUIPMENT ................................................................................................................ 16
EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES OFFSITES SYSTEMS STORAGE FACILITIES
Section Page ATMOSPHERIC STORAGE
XXII-B 2 of 49 EXXON
Date ENGINEERING
December, 1999 PROPRIETARY INFORMATION - For Authorized Company Use Only
CONTENTS (Cont)
Section Page
TANK GAUGING EQUIPMENT ............................................................................................................ 17
TANK HEATERS................................................................................................................................... 18
INLET DISTRIBUTORS FOR INTERNAL FLOATING ROOF (IFR) TANKS......................................... 18
MINIMIZING TANK INVENTORY.......................................................................................................... 18
TANK BOTTOMS AND LEAK DETECTION.......................................................................................... 19
SECONDARY CONTAINMENT ............................................................................................................ 19
SPECIAL TANK SERVICES ................................................................................................................. 19
ENVIRONMENTAL CONSIDERATIONS IN TANKAGE DESIGN ................................................................ 22

WATER EMISSIONS ............................................................................................................................ 22
SLUDGE AND SOLIDS EMISSIONS.................................................................................................... 22
AIR EMISSIONS ................................................................................................................................... 22
TYPES OF VAPOR EMISSION LOSSES ............................................................................................. 23
CONTROLS TO REDUCE AIR EMISSIONS FROM ATMOSPHERIC STORAGE TANKS .................. 23
SELECTION OF CORRECT TANK ROOF ........................................................................................... 23
FLOATING ROOF SEAL SELECTION ................................................................................................. 23
PRIMARY RIM SEALS.......................................................................................................................... 24
SECONDARY SEALS........................................................................................................................... 24
CONTROLLING EMISSIONS FROM ROOF FITTINGS ....................................................................... 24
COST EFFECTIVENESS OF CONTROL OPTIONS ............................................................................ 25
SUMMARY OF CONTROL OPTIONS FOR HIGH VAPOR PRESSURE STOCKS .............................. 25
DESIGN SPECIFICATION CHECKLIST....................................................................................................... 27

WERE THESE ITEMS SPECIFIED?..................................................................................................... 27
ARE ALL RUN-DOWN TEMPERATURES AND PRESSURES IN THE SAFE RANGE? ..................... 27
CHECK THAT THE FOLLOWING ITEMS WERE CONSIDERED ........................................................ 27
SAMPLE PROBLEMS .................................................................................................................................. 28

PROBLEM 1 (CUSTOMARY UNITS).................................................................................................... 28
PROBLEM 1 (METRIC UNITS)............................................................................................................. 30
PROBLEM 2.......................................................................................................................................... 31
PROBLEM 3.......................................................................................................................................... 33
APPENDIX A - TANK MIXING GUIDELINES ............................................................................................... 48

BASIC OBJECTIVES ............................................................................................................................ 48
TANK MIXING PARAMETERS ............................................................................................................. 48
GUIDELINES TO SOME MIXING PROBLEMS .................................................................................... 48
TABLES
Table 1 Comparative Emissions / Cost Effectiveness for Tankage Configurations /
Control Options .................................................................................................................................. 26

ENGINEERING Date
CONTENTS (Cont)
Section Page
FIGURES
Figure 1 Geodesic Dome Cover ................................................................................................ 35
Figure 2 Types of Floating Roofs............................................................................................... 36
Figure 3 Fixed Roof Tank With Internal Floating Cover ............................................................. 37
Figure 4 Petroleum Temperature Gravity Relations................................................................... 38
Figure 5 Semi-Automatic Water Drawoff Scheme With Automatic Tank Gauging..................... 39
Figure 6 Semi-Automatic Water Drawoff Scheme With No Automatic Tank Gauging ............... 39
Figure 7 Flexible Hose Drain ..................................................................................................... 40
Figure 8 Articulated Pipe Drain.................................................................................................. 41
Figure 9 Inlet Nozzle Diffuser .................................................................................................... 42
Figure 10 Low Suction Nozzle and Slotted Suction Details ......................................................... 43
Figure 11 Double Bottom Leak Detection .................................................................................... 44
Figure 12 Impermeable HDPE Liner Leak Detection ................................................................... 44
Figure 13 Secondary Containment and Tank Bottom Leak Detection ......................................... 45
Figure 14 Floating Roof Seals ..................................................................................................... 46
Figure 15 Rim-Mounted Secondary Seal..................................................................................... 47
Figure A-1 Typical Jet Mixer System............................................................................................. 49
Revision Memo
12/99 References have been updated. Appendix B has been rewritten to include
reference to DP XIII-B and it has been renamed Appendix A. Appendices A, C and
D have been deleted (now redundant). There have been some editorial changes to
bring this DP in line with the references, and with lessons learned from consulting
on recent problems and larger jobs.

Date ENGINEERING
SCOPE
This section covers the selection of the type of atmospheric storage tank, determination of tankage volume, and requirements for
associated tank equipment at refineries and chemical plants.
REFERENCES
DESIGN PRACTICES
Other Sections of Section XXII
Section XIII Mixing Equipment
Section XV Safety in Plant Design
Section XVI Thermal Insulation
INTERNATIONAL PRACTICES
IP 3-2-2, Foam System for Storage Tanks
IP 3-5-1, Fill and Discharge Lines, and Auxiliary Piping for Storage Tanks and Vessels
IP 4-8-1, Tank Foundations
IP 9-1-1, Spacing and Dikes for Storage Vessels and Tanks
IP 9-4-1, Atmospheric Storage Tanks
IP 9-7-1, Accessories for Atmospheric Storage Tanks
IP 9-7-3, Vents for Fixed Roof Atmospheric Storage Tanks
IP 9-7-4, Internal Floating Roofs for Atmospheric Storage Tanks
IP 15-1-3, Instruments for Storage Tanks and Vessels
API BULLETINS AND STANDARDS

1. API MPMS 3.1B, Manual of Petroleum Measurement Standards Chapter 3 - Tank Gauging, Section 1B - Standard Practice
for Level Measurement of Liquid Hydrocarbons in Stationary Tanks by Automatic Tank Gauging.
2. API MPMS 4.4, Manual of Petroleum Measurement Standards Chapter 4 - Proving Systems, Section 4 - Tank Provers (API
STD 1101, 2531, 2533, 2534).
3. API MPMS 19.1, Manual of Petroleum Measurement Standards Chapter 19 - Evaporative Loss Measurement, Section 1 -
Evaporative Loss from Fixed-Roof Tanks (Supercedes BULL 2518).
4. API STD 620, Design and Construction of Large, Welded, Low-Pressure Storage Tanks.
5. API STD 650, Welded Steel Tanks for Oil Storage.
6. API RP 651, Cathodic Protection of Aboveground Petroleum Storage Tanks.
7. API RP 652, Lining of Aboveground Petroleum Storage Tank Bottoms.
8. API STD 653, Tank Inspection, Repair, Alteration, and Reconstruction.
9. API STD 2000, Venting Atmospheric and Low-Pressure Storage Tanks Nonrefrigerated and Refrigerated.
10. API PUBL 2210, Flame Arresters for Vents of Tanks Storing Petroleum Products.
11. API RP 2350, Overfill Protection for Petroleum Storage Tanks.
12. API BULL 2521, Use of Pressure-Vacuum Vent Valves for Atmospheric Pressure Tanks to Reduce Evaporation Loss.
13. API STD 2550, Method of Measurement and Calibration of Upright Cylindrical Tanks, (ASTM D1220) (ANSI Z11.197) (R
1992).
14. API STD 2555, Method for Liquid Calibration of Tanks, (ASTM D1406–65).
➧ 15. API MPMS 7.4, Manual of Petroleum Measurement Standards Chapter 7 - Temperature Determination, Section 4 - Static
Temperature Determination Using Fixed Automatic Tank Thermometers.

ENGINEERING Date
REFERENCES (Cont)
OTHER LITERATURE
1. FAST-TABLET Users Manual.
2. Analysis of Atmospheric Storage Tank Pontoon Type Floating Roofs, ER&E Report No. EE.23ERL.70, June 15, 1970.
3. Safe Storage and Handling of Asphalts, ER&E Report No. EE.85.E.83, December, 1983.
4. Asphalt and Fuel Oil Plant Design Guide, ER&E Report No. MERP.4M.73, December, 1973.
5. Control of Hydrocarbon Emissions from External Floating Roof Tanks by Use of Secondary Seals, ER&E Report
EE.132E.79, November, 1979.
6. FLEXICOKING Unit Feed Tankage, EE Memo 81GE296, April 9, 1981.
7. Crude Storage Tank Cleaning, ER&E Report No. EE.124E.82, October, 1982.
8. Tank Maintenance Guide, ER&E Manual EETD 0050.
9. Automatic Crude Oil Sampling Handbook, ER&E Report No. EE.40E.84, May, 1984.
10. Frangible Roofs - Are They Needed? ER&E Report No. EE.36E.84, May, 1984.
11. Frangible Roof Protection for Fixed Roof Tanks, ESOC Communication 87-3.
12. Crude Tank Mixing and Sludge Control Guide, ER&E Report No. EE.18E.86, February, 1986.
13. Guidelines for Minimizing Nonwithdrawable Tank Inventory, ER&E Report No. EE.1M.86, August, 1986.
➧ 14. Hydrocarbon Measurement Practices, Exxon Company U.S.A. and Exxon Company International.
15. Water Drawoff Equipment and Guidelines for Improved Plant Operation, ER&E Report No. EE.4M.88, December, 1988.
16. Hydrostatic Tank Gauging, ER&E Report No. EE.5M.90, December, 1990.
17. Secondary Containment Design for Leak Detection in Aboveground Storage Tanks, ER&E Report No. EE.103E.91,
December, 1991.
18. NFPA 30, Flammable and Combustible Liquids Code.
19. Selection Guide for Storage Tank Emission Controls, ER&E Report No. EE.35E.93.
20. MEFA: Minimum Emissions Facilities Assessment, Section III, Emissions from Tankage, ER&E Report No. EE.12E.92,
February, 1992.
21. Methods of Reducing the Permeability of Tank Dikes and Pits, ER&E Report No. EE.30E.92, February 1992.
➧ 22. Tanks 3.1 - Storage Tank VOC Emissions Estimating Tool, ER&E Manual CPEE 162.
➧ 23. Refining Oil Loss Manual, ER&E manual EETP 048.
➧ 24. Updated Guidelines for Preventing Electrostatic Ignitions, ER&E Report EE.2M.98
➧ 25. Section XIII-B, Asphalt Operations, and Section XIII-E, Hot Oil Tankage, ER&E Safety Group's Safety Technology Manual
(ER&E Intranet), 1999.
➧ 26. EPA Publication AP-42, A Compilation on Air Emission Factors, Chapter 7.1, US EPA, September 1997.
➧ 27. Exxon Blue Book, ER&E Manual EETD 011 (Metric) or EETD 012 (Customary).
Note: Refer to EXXINFO technical report database for future additions.
DEFINITIONS
See Section XXII-A.
PRINCIPAL TYPES OF ATMOSPHERIC STORAGE TANKS

The two principal types of atmospheric storage tanks are fixed roof and floating roof. A brief description of each type follows:
FIXED ROOF TANKS

This type of tank has a fixed roof that is in the form of a cone or dome. The roof can be designed to be self-supporting in the
smaller sizes, but is normally supported by columns in the larger diameter tanks. The tank operates with a vapor space, which
changes in volume when the liquid level moves. Roof vents are provided to allow for vapor emission and to maintain the tank at
atmospheric pressure.
Fixed roof tanks may be either inert gas-blanketed or vapor space enriched if they for example contain low vapor pressure stocks
sensitive to degradation by oxygen or contain high flash stocks stored within 15°F (8°C) of their flash point.

Date ENGINEERING
PRINCIPAL TYPES OF ATMOSPHERIC STORAGE TANKS (Cont)
➧ GEODESIC DOME ROOFS

The use of geodesic dome roofs (refer to Figure 1) offers several advantages. Geodesic dome roofs are self-supporting, i.e., no
internal support columns are required, can be quite large [200 ft (61 m) diameter], and can be fabricated adjacent to the tank and
lifted into place. They are commonly used to cover external floating roof tanks to prevent rainwater and/or snow infiltration. The
roofs can be equipped with skylights, but care must be taken to specify window materials that are compatible with the product
stored. When skylights are specified, a permanent accessway to the skylights should be provided. The geodesic domes are
usually fabricated from aluminum. This creates a problem if the tank is used in inerted service (slight internal overpressure) since
aluminum and the shell steel have different coefficients of expansion and properly sealing all the roof to shell support joints is
difficult.
FLOATING ROOF TANKS

The floating roof tank is constructed so that the roof floats on the liquid surface. This eliminates the vapor space and greatly
reduces vapor loss. The three principal types of floating roofs are single deck pontoon, double deck and internal floating roof. A
brief description of each type follows:
Single Deck Pontoon Roof (See Figure 2) - The single deck pontoon roof consists of a flat center deck surrounded by pontoons
that are divided radially into a number of compartments. Because the roof is exposed to the weather, adequate drainage
facilities and buoyancy requirements must be provided per API 650. IP 9-4-1 covers the additional requirements for sizes larger
than 60 ft (18 m) in diameter. The design procedures in ER&E Report No. EE.23ERL.70 are still valid. External pan type
(without pontoons) floating roofs are not acceptable due to the ease of sinking the roof.
➧ Double Deck Roof (See Figure 2) - Double deck roofs have some advantages over single deck roofs, although they are
generally more costly. They have good resistance to wind-induced deflections, and there is little likelihood of overloading a
double deck roof with rainwater, since only small quantities can collect on it. The water will quickly spill into the emergency
drains even if the main drain is closed. Generally speaking, double deck roofs are used for large tanks [over 200 ft (61 m) in
diameter] and must be used for tanks over 300 ft (91 m) in diameter (IP 9-4-1).
Internal Floating Roof (See Figure 3) - The internal floating roof is installed in a cone roof or geodesic dome roof tank rather
than in an open top tank as with the single or double deck roofs. Internal floating roof tanks are generally used in lieu of
conventional floating roof tanks: 1) when changing existing fixed roof tanks into services requiring floating roofs, 2) where
excessive environmental loads due to rain, snow, and ice exist, and 3) when stock stored is sensitive to degradation by water
which could enter through seals in conventional floating roof tanks. The fixed roof eliminates the need for roof drainage
associated with conventional floating roofs. Such tanks are therefore especially well suited for cold locations, where maintenance
of the open top tanks is a substantial expense. Exxon Engineering's first preference from safety considerations is the open top
pontoon type floating roof tank; however, if internal floating roof tanks prove to be more attractive due to operating or economic
considerations as described above, they are acceptable from a safety standpoint.
Two basic types of internal floating roofs are currently available:
1. Aluminum Tubular Pontoon or Float Type Floating Covers (Figure 3) - Tubular floating covers are of the non-contacting
type, i.e., they are designed essentially as floating rafts and contain a vapor space of about 4 to 6 in. (100 to 150 mm)
between the liquid and the roof deck. Primary sealing of the vapor space is accomplished by a peripheral rim edge angle,
which projects into the liquid surface. For efficient sealing, the ring around the rim and other deck openings must project 6
in. (150 mm) into the liquid. The covers are constructed from thin aluminum sheeting which is supported on an aluminum
grid framework and air-filled tubular aluminum pontoons. Alternatively, rectangular aluminum floats filled with rigid
polyurethane are used. Another acceptable design uses a honeycomb panel between two thin aluminum layers (“Sanborn"
roof).
2. Pan Roof - These roofs are constructed of steel in the form of a pan. They are inherently unstable as they are provided with
no reserve buoyancy and no drainage capability. Because of problems with roof sinking, tanks with pan roofs are no longer
permitted (IP 9-7-4, Par. H.2.a).
Internal floating roof tanks are considered equivalent to open top, pontoon roof tanks for spacing. Foam facilities shall be
provided to supply total surface coverage, e.g., equivalent to coverage provided for cone roof tanks. Evaluation of design may be
necessary for tanks greater than 150 ft (45 m) in diameter and for storage temperatures greater than 150°F (66°C). For storage
applications at temperatures up to 180°F (82°C) and at diameters greater than 150 ft (45 m), the use of external single deck steel
pontoon or double deck floating roofs is recommended.
Due to service switches, environmental, or oil loss considerations, it may be necessary to retrofit an existing cone roof tank with
an internal floating cover. The designer should be aware that the utilization factor of a retrofitted cone roof tank could be greatly
reduced with the installation of an internal floating roof. One way to increase the utilization of these tanks is to add an additional
course to the tank shell and place a dome roof on top.

ENGINEERING Date
PRINCIPAL TYPES OF ATMOSPHERIC STORAGE TANKS (Cont)

Many proprietary designs are offered by vendors. New roof designs are continuously being developed and experience data with
existing designs are being accumulated. Because of this, it is advisable to obtain the latest status before proceeding with an
internal floating cover installation by contacting your TANKAGE SPECIALIST.
SELECTION OF THE TYPE OF ATMOSPHERIC TANK

For a given application, the designer will have to choose from among the types of atmospheric storage tanks described above,
based on the service requirements, the characteristics of the material to be stored and any other special local considerations.
Note especially that local laws governing air pollution control, fire protection and safety must be taken into account to insure that
the storage facilities selected will comply.
The following guidelines concern the choice between fixed roof and floating roof. If a floating roof tank is chosen, selection
among single deck pontoon, double deck, or internal floating cover should be based on the information given on these types
under PRINCIPAL TYPES OF ATMOSPHERIC STORAGE TANKS, above.
EXTERNAL FLOATING ROOF TANKS

Floating roof tanks should be used for the services listed below. This summary is based on experience, safety considerations
and economic studies.
Static Accumulators - Stocks that are classified as intermediate vapor pressure static accumulators per Section XV-B,
Minimizing the Risks of Fire, Explosion or Accident.
Flash Point - Stocks which are to be stored at temperatures within 15°F (8°C) of their flash points, or higher.
Type of Stock - All crude oil stocks.
Tank Size - All tanks with diameters exceeding 150 ft (45 m), if they are to contain low-flash stocks (flash point 100°F [38°C] or
below). Within recent years, low flash stocks have been stored in floating roof tanks regardless of diameter to limit fire risk and
environmental concerns.
Oxygen Sensitivity - High vapor pressure stocks which are sensitive to degradation by oxygen (e.g., coker naphtha). For this
service, the toroidal type of seal is preferred. (Low vapor pressure stocks, which are oxygen-sensitive, should be stored in fixed
roof tanks with nitrogen or inert gas blanketing.)
Other - Special considerations may require storage in fixed roof tanks or fixed roof tanks with internal floating roofs. Examples
include the use of cone roof tanks with vapor recovery for high RVP stocks due to stringent hydrocarbon emissions requirements.
Also, due to a combination of snow loads (which dictated the need for fixed roofs) and location within an earthquake zone (which
raised the concern of floating roofs hanging up due to out of roundness tank walls), the crude tanks for the Valdez terminal were
installed as vapor-blanketed, cone roof tanks.
INTERNAL FLOATING ROOF TANK

Fixed roof tanks with internal floating covers are generally used in lieu of conventional floating roof tanks when:
1. There is a need to change service of an existing fixed roof tank to one that requires a floating roof tank.
2. Excessive environmental loads due to rain, snow and ice exist.
3. The stock stored is sensitive to degradation by water, which could enter through seals in conventional floating roof tanks.
4. It is economically more feasible.
From a tank spacing standpoint, where equivalency to an external floating roof tank is desired, the use of internal floating covers
is limited to tanks with a maximum diameter of 150 ft (45 m).
FIXED ROOF TANKS

Fixed roof tanks are used for all atmospheric storage where floating roofs are not required or not practical. They are also used
where inert gas blanketing or vapor space enrichment is required. Examples of these situations are:
1. Low vapor pressure stocks subject to stringent hydrocarbon emission requirements or sensitive to degradation by oxygen.
2. High flash stocks stored within 15°F (8°C) of flash point (hot tanks).
3. Areas of high seismic activity where there is a concern that floating roofs may hang up due to out of roundness of tank walls.
4. Areas of heavy snow loads like Alaska, which dictate a need for fixed roof tanks.
5. Future restrictions in environmentally stringent areas may require fixed roof tanks, vapor balanced with loading facilities and
vapor recovery. Floating roof designs may not be adequate even if equipped with secondary seals.
➧ 6. For products that cling to the shell walls and would prevent the free movement of a floating roof, for example asphalt.

Date ENGINEERING
BASIC DESIGN CONSIDERATIONS

Tankage design involves determining the number and sizes of tanks required to support refinery operations. Various tankage
services include feed tankage, intermediate tankage, component blendstock tankage and finished product tankage. Siting
tankage within the refinery borders is also a major design consideration. Evaluation parameters include safety, economic and
environmental factors. Other factors to be considered in the overall evaluation of tankage needs follow.
DESIGN VALUES FOR INNAGE AND OUTAGE

The following table represents the minimum values for innage and outage to be used for computing the gross tankage volume.
The innage value will vary according to the nozzle size [nominal 12-in. (300 mm) nozzles were used] and nozzle configuration
used but the table below provides reasonable figures to be used for planning purposes. Refer to ER&E Report No. EE.1M.86 for
minimum tank innage for specific nozzle sizes and configurations. For new tanks, the designer needs to be specific regarding net
(working) volume requirements. Refer to IP 9-4-1, Par. 6.2 for definition of shell height definition and the potential need for shell
extensions. Refer to IP 9-7-1, Par 8.4 for overflow slots requirement. For existing tanks, specific details of roof design need to
be verified.
TYPE OF TANK INNAGE, in. (mm) OUTAGE, in. (mm)(4)

External Floating Roof(3) 36 (910) 18 (460)
30 (760)(1) 12 (300)(2)
Internal Floating Roof(3) 31 (790) 18 (460)
25 (635)(1) 12 (300)(2)
Fixed Roof 22 (560) 18 (460)
12 (300)(2)
Notes:
(1) Applies when remote level instrumentation is used.
(2) Applies when the tank is equipped with a reliable system of centralized level instrumentation and valve control.
(3) Outage for floating roof tanks can be significantly greater for certain floating roof designs, e.g., double deck, foam dam
details, etc. unless the top of the tank shell is extended.
(4) Outage amounts may need to be increased in earthquake zones to provide additional freeboard to minimize “sloshing"
overflow from tankage.
ECONOMIC TANK SIZING

The following guidelines apply to tank size, number, and height/diameter.
Size - In general, the cost per barrel (cubic meter) of tankage decreases with increasing tank size (subject, of course, to
limitations on maximum practical size). However, operating flexibility is generally greater with a larger number of smaller tanks.
Tank sizes can range from a low of about 10 kB to over 500 kB in a refinery.
Number - At least two tanks are usually provided for each finished product service. The actual number provided is a function of
the following factors - total volume requirements, the need to separate rundown tankage (from a unit or blender) from certified on-
spec finished product tankage, parcel size of shipments, customs requirements, and tank maintenance.
Height vs. Diameter - The maximum tank height should be specified based on soil conditions, local fire codes and structural
design considerations such as maximum shell thickness, in order to minimize the amount of land area required. An exception to
this is that for floating roof tanks, the height to diameter ratio should not exceed 1.0, to permit roof access by way of a rolling
ladder.
➧ For a large tank, a typical height is 48 or 56 ft (14.5 or 17 m). Heights have traditionally been specified in 8 ft (2.4 m) increments
to match the dimension of standard shell plates. However, other plate widths are available, and tank contractors may suggest
using other plate widths if economical (wider plates minimizes welding requirements at the expense of more steel). Tank heights
of 64 ft (19.5 m) are occasionally used. Greater tank heights are possible for refrigerated LPG/LNG services due to the low
density of the stored liquid.
STRUCTURAL DESIGN CONSIDERATIONS

The primary structural requirements governing the design, fabrication, erection and inspection of atmospheric storage tanks are
covered in the International Practices. The International Practices are based on, and are supplemental to, API Standard 650,
Welded Steel Tanks for Oil Storage. In locations where API Standards are mandatory, or where more stringent local codes exist,
such standards and codes must be followed.

ENGINEERING Date
BASIC DESIGN CONSIDERATIONS (Cont)
TANK HEATING
The tank contents should always be maintained at a temperature at least 15°F (8°C) above the pour point, or sufficient to keep
the kinematic viscosity from exceeding 300 cSt (300 mm2/s), whichever is greater. If the minimum ambient temperature is cooler
than this, tank heaters should be specified. Calculation of heat losses from tanks and design of tank insulation are covered in
Section XVI, Thermal Insulation.
TANK MIXERS
➧ Services for which mixing equipment should be specified are listed below, with an explanation of the purposes served by the
mixers. Design and/or selection of mixing equipment is covered in Section XIII, Mixing Equipment, and APPENDIX A.
Two types of mixers are generally recommended: 1) The side entry propeller (SEP) mixer and 2) The jet mixer. The jet mixer is
not suitable for mixing high viscosity fluids like heavy heating oils and asphalt, but it is more suitable for automotive diesel oil and
lighter materials. The SEP mixer is appropriate for all applications. The choice between the two is usually made based on
economics.
Butterworth P43 machines can also be used in place of jet mixers. However, the installed cost of these machines is much higher
than a jet nozzle and they should only be considered if a very short mixing time is required. They are not in wide use but they are
excellent for controlling sludge buildup and resuspending settled sludge in crude tanks.
Crude Tanks - Side entry propeller type mixers should be specified for all crude tanks. The mixers serve the following purposes:
1. To prevent the deposition of wax from waxy crudes.
2. To allow slop to be blended with crude.
3. To maintain BS&W in suspension.
Product tanks that contain a stock produced by the blending of two or more components and/or additives should be equipped
with mixers. Mixing can be accomplished by a jet nozzle with a recirculation system or by SEP mixer. The final selection should
be based on economics. The mixing is required for the following reasons:
1. To prevent stratification of components within the tank.
2. To allow for re-mixing after the addition of a component to adjust an off-test blend.
3. To prevent temperature stratification in large hot oil tanks [above 265°F (130°C)].
Blend Stock Tanks - The rundown line should be equipped with a jet nozzle. This will ensure uniform blend stock quality. A
recirculation system is not usually required.
Intermediate Tanks - The rundown line should be equipped with a jet nozzle. If, however, the downstream unit can be upset by
feed that is not consistent in quality, a recirculation system or propeller mixer should be used instead. The selection should be
based on economics.
LOCAL SITE CONDITIONS

Elevation above sea level is important, because it directly affects the true vapor pressure limitation placed on stocks stored in
atmospheric tankage. At sea level the maximum allowable true vapor pressure is 13 psia (90 kPa absolute). For each 1,000 ft
(300 m) elevation above sea level, this value must be reduced by 0.5 psi (3.5 kPa).
Ambient Temperature - The maximum and minimum ambient atmospheric temperatures should be determined. This
information is needed to classify the hydrocarbon into the appropriate vapor pressure and flash point class.
TANKAGE REALLOCATION
Changes in product slate, product movement pattern, or parcel sizes may indicate the desirability of re-allocating existing tankage
to different services. A detailed check of what changes are required to the existing tankage and piping system is needed to
establish the practicality of the proposed changes. Although tank reallocation often appears desirable when comparing available
vs. required tankage by service, layout and piping constraints often combine to make the cost of tank reallocation very high.
When existing tankage is allocated to new product classes, e.g., high flash cone roof tanks converted to low flash service, diking
capacity and spacing criteria require re-evaluation for the new service.
STOCK CLASSIFICATION
The liquid to be stored must be classified into the appropriate static and vapor pressure class, according to the criteria given in
Section XV-B, Minimizing the Risks of Fire, Explosion or Accident. This information is required, to determine whether a floating
roof tank must be specified for safety reasons.

Date ENGINEERING
BASIC DESIGN CONSIDERATIONS (Cont)
ENVIRONMENTAL IMPACT ON TANK BOTTOM DESIGN

➧ Secondary containment and leak detection are now required in many parts of the world to protect the environment from
accidental leaks and spills. Of primary concern is a leak from the bottom of an aboveground storage tank.
For bottom leaks, there are two designs now being recommended. They are:
• Double steel bottom tank design. This is the most flexible one since it can be used for existing tanks and in new tank
construction. However, it is more costly and seldom used for new construction.
• Impermeable membrane installed in the tank foundation beneath the tank bottom. This design is suitable only for new
construction and is described in IP 4-8-1, Tank Foundations.
For tank farm spills, the issue of secondary containment encompasses the entire diked impounding area. This brings into
question the permeability of the soil comprising the impounding area and dikes and its adequacy to protect the environment
beyond the refinery grounds. The trend in legislation is to require the installation of impermeable membranes to enclose these
areas.
DESIGN PROCEDURES
SIZING CRUDE TANKAGE

Crude is delivered to a refinery by either tanker or pipeline. Refinery crude storage is necessary to prevent unplanned runouts
and costly tanker delays and occasionally to meet government-mandated compulsory storage requirements.
There are three basic ways to determine optimum crude storage requirements when received from tankers: crude circuit
simulation model, Tankage and Blending Evaluation Tool (FAST-TABLET), and the parcel size plus advance and delay method.
Compulsory storage requirements would be additive to the working volume.
Crude Circuit Simulation Model simulates the crude supply system. This model is applicable for regional studies and is
normally run by regional logistics or supply departments.
➧ FAST-TABLET (Facilities Assessment Simulation Tool - Tankage and Blending Evaluation Tool) is an Exxon developed
computer stochastic simulation tool. In the oil movements and storage area, it can be used to evaluate crude and product
tankage, and associated marine facilities (number of berths, loading lines, loading rates). Optimization is achieved by entering
facilities data into the model, running alternative cases, and developing economics outside of the model runs. Typical FAST-
TABLET runs simulate several years of operations.
➧ Parcel Size plus Advance and Delay is an approximate method that should be used with engineering judgement. It sizes crude
tankage through the use of experience factors involving the number of advance and delay days associated with moving crude
from a particular source to the refinery. The total barrels of tankage required for crude volume is arrived at by the following
empirical formula:
Crude Volume = Maximum Parcel Size + Pipestill Stream Day Feed Rate
x (Advance Days + Delay Days + Pumping and Settling Days)*
* The total number of days normally ranges from 5 to 15.
The terms are described as follows:
1. Maximum Crude Parcel Size is the volume of the largest anticipated crude receipt at the refinery.
2. Days of Advance and Delay represent the number of days, which correspond to the anticipated deviations between a
planned arrival time and an actual arrival time. The number can be determined for rough estimates on the previous
experience of the refinery. Advance days are associated with shipments arriving ahead of schedule and require crude
tank space. Delay days are associated with shipments arriving late and require crude tank stock to maintain pipestill
supply.
➧ 3. Pumping and Settling Time - The pumping time is the time required for the tanker to discharge the maximum parcel
size. Most tankers have pumping capability to discharge their cargo within 24 hours. The settling time is the time
required to settle the crude and draw off the water. Settling time depends on the degree of cleaning of the crude tanks;
typical settling times in clean tanks is 1/2 to 2 days. This time increases should there be a sludge problem due to either
the receipt of heavy or special crudes, or if existing mixing facilities are not efficient or are underpowered.
This technique can also be used to size crude tankage for refineries that are supplied by a pipeline. The maximum parcel
size would correspond to the maximum pipeline receipt size, and the advance and delay days would be equivalent to the
anticipated outage time, which can be obtained from the pipeline operators.

ENGINEERING Date
DESIGN PROCEDURES (Cont)

Crude Sampling - The increased importance of oil loss control has placed accurate and reliable determination of the sediment
and water content (BS&W) and the average density of crude oil transfers among the prime concerns of the petroleum custody
transfer operation. Sampling techniques applied to tanks and ships' compartments do not give reliable or representative
samples. Sampling of crude oil flowing in a pipeline has been shown to be effective provided careful attention is given to the
pipeline conditions, sampling system design, sample handling, and transfer of sample for lab analysis. Refer to ER&E Report
No. EE.40E.84 for information on the design of a sampling system.
SIZING PRODUCT TANKAGE

The basic variables which set the requirements for net product tankage volume are working storage requirements (includes
seasonality), unit turnaround protection and compulsory storage requirements. Each of these is discussed below.
To determine the total volume, one calculates the minimum volume necessary for working storage and compares this with the
volume required for turnaround protection. The larger number is then the design capacity for the product tankage. Compulsory
storage is normally added to this, to give the total volume of product tankage that must be provided. Blend stock, sometimes
referred to as component tankage, is considered part of the product tankage.
A spreadsheet is a convenient format to use for evaluating product tankage requirements. Although the spreadsheet is not a
dynamic model or stochastic simulation of the production and distribution system, it does provide the tankage planner and
designer with a deterministic method for rapidly seeing how tankage requirements for each product are affected by changing key
variables, e.g., advance/delay factor, production rate, etc. The spreadsheet is very applicable to evaluating changes to existing
refinery operations since experience is available on the level of fluctuations in the distribution system.
Each refinery will have its own set of priorities, specific scenarios to handle, and desired flexibility. Consequently, it is not
possible to present a list of rules. However, the following items should be checked in developing an allocation plan for product
tankage:
• Provide storage for each product for maximum parcel size as defined by Refinery. Size may vary according to product.
• Provide advance/delay/safety margin for:
- Early ship arrival.
- Late ship arrival.
- Customs clearance.
- Lab testing if on-line analyzer values not acceptable.
- Batch blending time.
• Consider two tanks for each major product to allow blending during loading.
Product Tankage (Net) = Maximum Parcel + (Advance + Delay + Safety) days x Stream Day Production Rate
SIZING COMPONENT TANKAGE

Sizing of component tankage is based on the specific blending flexibility required by a refinery.
Typical considerations are:
• Maximum component volume for the product batch. Product batch size is normally one product tank volume.
• An allowance for “advance/delay" in blending/shipping schedules. An example would be 3 days for Mogas and 2 days for
distillate, which is easier to blend.
• Turnaround storage to cover short repeatable events such as reforming unit regeneration. Unit turnarounds (30 to 60 days)
are generally scheduled in complementary unit blocks to eliminate large storage requirements.
• Blocked operation of certain units to maximize yields but which result in discontinuous component production.
Working Net Storage Requirements - Working (net) tankage is composed of three basic components. The first is maximum
parcel size, or the amount of tankage required for refining and transportation operations when production and demand are in
balance. The second, referred to as vessel advance/delay factor, allows for imbalance that occurs due to variations from ideal
demand and transportation conditions. This portion is expressed in terms of equivalent unit production days and is calculated
from experience numbers supplied by the refinery or affiliate. The total advance/delay will normally range from 5 to 10 days.

Date ENGINEERING

The third portion is that additional tankage volume required to contain (during the off-season) excess production of a product that
has a seasonal variation in demand. During the period of higher than average annual demand, this pre-stored product is
withdrawn from inventory to supplement current production. Over the years, the need for seasonal storage of products at the
refineries has decreased in general. Product rate variations can be handled in other ways than storage at the refinery, such as
adjusting the refinery's running plan to be in line with the seasonal product demand pattern. In addition, marketing tankage and
other supply system flexibilities are utilized to minimize the need for tanks and inventory to handle seasonal product rate swings.
The minimum working volume is calculated as follows:
Minimum Working Volume = Maximum Parcel Size
+ (Calendar Day Throughput) x (Days Advance + Days Delay)
(% Seasonality )
+ (Calendar Day Throughput) x (365 CD/yr)
100
Note: Typical volume units are Bbl or cubic meters.

The maximum parcel size is typically used in the above calculation. On occasion, however, the arrival frequency of vessels
calling for average size parcels is such that tankage is required for several average size parcels (since this volume is greater than
the maximum single parcel).
Unit Turnaround Protection - This tankage is required to cover demands during the period when the production unit is down.
This volume is calculated as follows:
Volume = (Number of Turnaround Days) x (Calendar Day Throughput)
Before this volume is established, the economics of alternative methods of providing product during the turnaround period should
be examined. For some locations the following approaches have proved more economical than investments in tankage.
1. Exchange arrangements with other refineries.
2. Supplementing supplies by obtaining product from another circuit refinery.
3. Increasing tankage availability at marketing distribution locations.
Compulsory Storage Requirements - Compulsory storage of products (for use in time of crisis) is a government requirement at
certain locations. Normally, these volumes cannot be figured into the net design capacities and are over and above that required
for working tankage or for turnaround protection. Some countries also require compulsory storage of crude. The rules for
calculating compulsory storage requirements are very site specific and often require interpretation by the local affiliate.
Number of Product Tanks - No simple technique is available to determine the individual sizes and number of tanks to make up
the final total product volume. An approach that takes into account the basic guidelines listed below should be used.
1. Specify at least two tanks per grade if the grade is produced continuously from a unit or blender. This is because the
rundown stream should not be filling a tank while a shipment is being loaded out of the same tank.
2. Match product parcel sizes with net tankage volume. This will help to prevent situations where one parcel requires the use
of one whole tank and a part of another. This situation ties up the remaining usable space in the second tank and is not
desirable if it is likely to occur often.
3. Depending on the frequency of simultaneous by-land and marine movements of the same product, a separate by-land day
tank may be required to separate by-land and marine shipments. These day tanks are often part of a separate marketing
operation.
SIZING INTERMEDIATE TANKAGE

Intermediate tankage is storage for an intermediate product that will be used as feed to another unit. The following guidelines
should be used for developing volume requirements for intermediate tankage:
Turnaround Schedule - Determine the turnaround schedules for the producing and consuming units involved. This schedule
should consider mechanical maintenance as well as process related operations such as catalyst regeneration if applicable.
Volume Requirement - Determine the volume required to store surplus production of the upstream unit during the turnaround of
the downstream unit, and to provide feedstock for the downstream unit during the turnaround of the upstream unit. This will
depend on which unit has the longer turnaround and whether they occur at the same time. The greater of the two volumes is the
volume required. Alternative uses or sources for the intermediate product are sometimes more economically attractive than
providing dedicated tankage for this purpose.

ENGINEERING Date
GROSS TANKAGE VOLUME

The previous section described procedures for determining net tankage volume for various refinery streams at 60°F (15°C). The
volume occupied by thermal expansion of the stored fluid and the unusable volume inherent in all tank designs need to be added
to net volume to quantify tank dimensions. These additions are covered below.
Innage and Outage Allowance - These values reflect non-usable portions of tank contents.
Innage is minimum static inventory in a storage tank. This is the liquid remaining below the lowest normal pumping level. It is
expressed as the distance from the lowest bulk liquid level to the tank base line. See BASIC DESIGN CONSIDERATIONS for
recommended innage and outage values.
Outage is the space left at the top of a storage tank to provide a safety margin to prevent spillover during filling. It includes an
allowance for the floating roof pontoon and an allowance to give the operator time to take corrective action. It is expressed as
the distance measured from the top of the tank shell to the maximum allowable bulk liquid level. Generally, 18 in. is allowed for
working volume unless a motor operator fitted with a high level cutout is provided to close the inlet valve which permits reduction
to 12 in. Alternatively, high level alarm/cut out points are defined in time units to allow for operator intervention. For example, on
a recent project, the first high-level alarm point (HLA) was at 30 minutes before overfilling at the maximum filling rate. This HLA
was generated by the tank gauging instrument. A second independent instrument alarm, high high level alarm (HHLA) was
provided at 25 minutes before overfill. For specific applications, setting alarm points should be reviewed with the Safe
Operations Committee (SOC) or equivalent.
Caution: Refer to specific tank details to determine outage and maximum fill levels. Shell extensions are sometimes used to
avoid having floating roof seal weather shield, secondary seal, or primary seal extend above the shell/shell extension
in normal operation.
Thermal Expansion Requirements - This is an allowance resulting from temperature changes of the contents during storage.
Frequently, it is considered as outage, however, it is recommended that the working tankage volume be determined for the
maximum tankage holdup temperature using the hot material specific gravity for volume calculation. Figure 4 is provided to
determine this value. Similar data is available in the Blue Book.
Tank Size - Specify the largest single tank (if possible; otherwise minimize the number of tanks) which will meet the volume
requirement.
TANK ACCESSORIES
The basic requirements for tank accessories to be included in the tank specification are summarized below:
Tank Nozzles
FLOATING ROOF TANK FIXED ROOF TANK
NOZZLE SERVICE NOZZLE SIZE TYPE NOZZLE NOZZLE SIZE TYPE NOZZLE
Steam(1) All API Low All API Low

Condensate All API Low All API Low
Water Drawoff All API Low All API Low
Oil Inlet < 12 in. (300 mm) API Low All API Low
Oil Inlet ≥ 12 in. (300 mm) Flush All API Low
Oil Outlet < 12 in. (300 mm) API Low < 8 in. (200 mm) API Low
Oil Outlet ≥ 12 in. (300 mm) Flush ≥ 8 in. (200 mm) API Low (Elbow Down)
Jet Nozzle All API Low All API Low
Notes:
(1) When the design requires that the steam inlet nozzle be elevated above the condensate nozzle, the steam inlet nozzle may be
specified as an API Standard type nozzle up to and including 6-in. (150 mm) diameter.
(2) When jet nozzles are used in floating roof tanks, it should be specified that the roof be designed so that there is no interference
between the jet nozzle and floating roof when the roof is in the lowest landed position.
(3) The maximum allowable size for an API type nozzle is 30-in. (760 mm).
(4) The largest allowable flush type nozzle size is 24-in. (610 mm). If additional capacity is required, multiple flush type nozzles should be
used.

Date ENGINEERING
(5) The minimum allowable size water drawoff for crude tanks is 6-in. (150 mm).
(6) Consider the use of high or floating suctions in unit feed and distillate product tanks to minimize water entrainment. (Note that a fixed
high suction will increase tank innage.)
(7) The inlet and outlet nozzles must be designed per API 650 and the International Practices such that the piping design satisfies
allowable loads on these nozzles. This requirement should be part of the tank specification.
(8) Although the API permits the use of flush type nozzles down to an 8-in. (200 mm) diameter, API low nozzles are recommended in 10
in. and smaller sizes in product tankage due to product contamination considerations.
Water Drawoff - All tanks in hydrocarbon service shall be provided with a minimum of one water drawoff connection using an
API low type nozzle. If a cone bottom up tank is used with a diameter greater than 20 ft (6 m), a water drawoff sump is required.
Cone bottom down tanks do not require a water sump. For these tanks, the water is collected from the low point in the center of
the tank using an elbow down pipe drawoff line. The vast majority of tanks are of the cone bottom down type. Various schemes
to perform this operation automatically have had varied success over the years. One of the major problems is detecting the
oil/water interface.
WATER DRAWOFF EQUIPMENT

The existence of an immiscible water phase or suspended oil water phase at the bottom of atmospheric storage tanks is quite
common. It is important that this accumulated water be periodically removed as its presence increases tank bottom corrosion
and promotes biological growth. In the past, this water was removed manually, that is, the water drawoff valve was opened, the
outflow observed until free oil appeared, and then the valve was shut. Semi-automatic drain valves, which take advantage of the
difference in density between the oil and water, have been used but have not gained wide acceptance due to difficulties
experienced in sensing certain oil/water emulsion interfaces and failure of the valves to operate reliably.
Closed drawoff systems from individual tanks to one or more dedicated slop tanks have proven quite successful at locations
where adequate tankage exists.
Improvements to the basic unassisted manual drawoff operations are obtainable using commercially available technologies which
offer reductions in manpower requirements, minimize the quantity of oil drawn from the tank with the water, and reduce operator
exposure to the products.
Over and above the water drawoff line required per the International Practices, there are recommended facilities that permit the
recovery of oil remaining in the drawoff line from the previous operation that would otherwise be drained to grade. Alternative
options include the following:
• Hard pipe the water drawoff line to a local catch basin for eventual oil recovery in the waste water treating system.
• Provide a hand pump and recycle line to pump the line contents back to the tank prior to water drawoff. A sight glass in the
line allows the operator to see when the oil is displaced and water is present.
• Provide a small local drum to contain the contents of the drawoff piping. The drum would then be periodically emptied via a
vacuum truck, or the oil recycled to tankage.
• Locate the apex of the floor cone off-center, i.e., near to the WDO nozzle to minimize oil in the WDO line.
Current designs should consider a combination of in-tank and in-line hydrocarbon/water interface detection technologies. The in-
tank interface measurements are utilized to indicate when a drawoff operation is required and the quantity of water within the
tank. The in-line interface detection is utilized to terminate the operation when the first traces of oil are present in the drawoff line.
The operation can be made semi-automatic with the use of an on/off type control valve in the drawoff line. Two basic methods
may be used: one in conjunction with tank level gauging (Figure 5) and the other in conjunction with a totaling flow meter (Figure
6); both cases use a % oil switch and an on/off control valve in the drawoff line. Refer to ER&E Report No. EE.4M.88 entitled
Water Drawoff Equipment and Guidelines for Improved Plant Operation for further details. Caution: Verify reliability for specific
applications.
Roof Drains for External Floating Roof Tanks - Roof drains are provided to remove rainwater from the top of floating roofs.
See Figures 7 and 8. Drains are usually jointed articulated pipes or hoses. Design is per API 650. In addition, the capacity of
the drain shall be such that the maximum accumulation occurring on the roof membrane during the maximum design rainfall
conditions is less than 1 in. (25 mm). This must be accomplished when the roof is in the lowest floating position.
The preferred roof drain is shown in Figure 7 with the use of a high-grade flexible hose. These hoses contain a flexible stainless
steel carcass and an impervious outer layer consisting of a thermoplastic or other material. They provide a repeatable “lay"
pattern, minimizing the potential for hose damage during roof travel. One supplier of high-grade flexible hose is Coflexip and
Services Incorporated of Houston, Texas.

ENGINEERING Date

Articulated pipe drains are susceptible to corrosion at the ball races in the swivel joints. Flexible Rigid/Pivot drains avoid the
corrosion problem by achieving flexibility through “pivots" which enclose short flexible hoses. One supplier of the Flexible
Rigid/Pivot drain is HMT Corporation of Houston Texas.
Roof draining is normally a manual operation. The bottom drain valve is left closed to avoid spilling product in the event a leak
develops in the articulated pipe drain or hose. Where rainfall is expected to exceed 10 in. in 24 hours, automatic roof drainage
should be provided. This is done by installing a special ball valve in place of the manual shutoff valve. This valve will
automatically open when exposed to water and close when exposed to hydrocarbon that is lighter than water.
The following are roof drain valves that are commercially available:
Ludlam Sysco (Russel) Ball Valve, Systems and Components Ltd., Wiltshire, England
Fushiman Type A103-1ADB Water Drain Valve Fushiman Co., Ltd. Tokyo, Japan
HMT Checkmate Hydrocarbon Sensing Valve HMT, Inc., Houston, Texas
Belfield Decantation Valve, Dewmark Products, St. Charles, Illinois
Floating roofs are sometimes provided with emergency drains. The emergency drain will allow water to pass through to the
hydrocarbon side of the roof and settle to the bottom of the tank in the event the drain line plugs. Emergency drains are usually
provided on all double deck roofs and permitted on single deck roofs where the pontoon area is at least 50% of the roof area.
Freeze protection for roof drains is an important consideration in cold climates. Some suggestions in this regard and in order of
preference are:
1. Electrically heat trace and insulate valve and piping outside the tank.
2. Add anti-freeze to the drain system. Must replace anti-freeze after each use.
3. Crack open block valve at grade during freezing weather. Develop and implement written operating procedures, which will
minimize any leakage of hydrocarbon and will call for opening and closing the valve at the appropriate times.
Floating Roof Tank Seals - These seals serve several functions. They close the annular rim space of the roof, assist with
centering of the floating roof yet permit normal roof movement, maintain lightning strike protection, control evaporation loss, and
minimize atmospheric pollution. A seal system can consist of one or two separate seals. The first seal is called the primary seal.
The installation of a secondary seal above the primary seal can significantly reduce emissions by providing an additional barrier
through which vapors must pass. In addition, some seal systems include a weather shield. EPA Publication AP-42 provides
methods of estimating hydrocarbon vapor releases with various seal arrangements. In the U.S., secondary seals are becoming
required emission control technology on external floating roof tanks storing volatile hydrocarbon liquids. Refer to Environmental
Considerations in Tankage Design for further details on tank seals.
Roof Vents - Roof vents are used to allow inbreathing and outbreathing of the vapor space below the roof. Inbreathing is caused
by drawing product out of a tank or by a drop in temperature which causes the gases in the vapor space to contract.
Outbreathing is caused by filling a tank and thereby displacing the vapor volume with liquid volume. A rise in the vapor space
temperature also results in outbreathing by virtue of expanding the gases occupying the vapor space. Changes in barometric
pressure will also result in either inbreathing or outbreathing.
Other sources of outbreathing are air agitation and fire exposure. Air agitation to mix tank contents is not recommended based
on environmental and safety considerations. However, provision must be made to relieve pressure buildup, which may occur due
to fire exposure at or near the tank. Such heating effect would tend to boil off additional vapors and expand them to such an
extent that tank design pressure would be exceeded if additional emergency venting is not provided. In most large tanks, no
additional emergency vents are required since fixed roof tanks are built in accordance with API 650, which calls for a weak roof-
to-shell seam design.
Refer to API Standard 2000 for estimating venting requirements for atmospheric storage tanks. Note that if the API-2000 venting
requirement is used to calculate inert gas make-up rates to prevent vacuum, a very high inert gas supply rate will result. This is
due to the built-in conservatism to protect the tank roof and shell from vacuum, and the fact that open vents are very cheap to
build big. A detailed study of the actual temperature, pressure and product movements should be completed to set inert gas
make-up rates.
➧ Fixed roof tanks are provided with either pressure-vacuum (PV) vents or open type vents. The PV vent is used on all fixed roof
tanks, which contain products with a flash point below 100°F (38°C) or where the product temperature will normally be within
15°F (8°C) of the product's flash point. For environmental reasons (odor abatement), some locations now require fixed roof tanks
storing hot product to use a PV vent. If this hot product would tend to plug a PV vent, the PV vent shall be purged with a gas
injected at the vent (IP 9-7-3, Par. 3.2.b.). It is suggested to consider heat tracing the vent as well.

Date ENGINEERING

Fixed roof tanks with internal floaters (IFRs) must be provided with numerous large free openings (0.2 ft2 for each ft of diameter)
to assure free ventilation between outside air and vapor space bounded by the fixed roof and the floating roof. Under no
circumstance should IFR tanks be operated with PV or similar vents unless the vapor space is inerted or enriched. IP 9-7-3
covers additional requirements to vents on fixed roof tankage.
TEMPERATURE INSTRUMENTS
1. Temperature indication shall be provided for all atmospheric storage tanks. Single point temperature measurement shall be
used for unheated low-viscosity [below 36 centistoke (mm2/sec)] products. Multi-point measurement techniques may be
required for tanks containing other products, as well as those where temperature stratification exists. Temperature elements
such as the single point temperature sensors shall be provided with a thermowell.
➧ 2. On tanks where an accurate volume measurement is required, such as custody transfer applications, or the temperature
needs to be known for safety reasons, high accuracy temperature sensing devices with remote indication shall be provided.
The overall accuracy of the measurement system, including the sensor, transmission, and readout devices, shall be as
stated in IP 15-1-3. This is hardware accuracy only and does not include errors due to the placement of the thermowell or
stratification in the tank. Refer to Hydrocarbon Measurement Practices for further requirements.
3. Single point temperature sensor shall be located in the vicinity of the tank outlet nozzle at a preferred elevation of 5 ft 6 in.
(1.7 m) above the tank bottom providing that on a floating roof tank this will not interfere with the floating roof at its lowest
position. If interference is a problem, the preferred alternative minimum height above the tank bottom is 2 ft 6 in. (0.75 m).
The sensing point shall be located approximately 3 ft (1.0 m) inside the tank wall such that it will not be unduly affected by
the tank heaters or internals, where specified.
4. A dial thermometer in a thermowell shall be installed adjacent to each tank's single point temperature sensor to serve as a
local indicator. The dial thermometer and thermowell shall be at the same height and shall have the same immersion length
as the single point sensor. The thermometer and single point sensor should be located in close proximity to the automatic
level gauge for consistency in tank measurements.
5. The specific connection requirements for temperature measurement instruments depend on the type of the storage tank and
the type of automatic tank gauging equipment used. Refer to the International Practices for the instrument design and
installation requirements, along with detailed sketches showing connection locations and orientation.
6. Heated tanks shall be equipped with self-actuating temperature controllers, unless the heating medium temperature is
selected so that it can never exceed the process needs. The sensing point for the temperature controller shall be at the
same location as the dial thermometer. Provisions shall be made to automatically shut off tank heaters when they become
exposed above the liquid level. High temperature alarms are optional but should be considered when the temperature can
reach within 15°F (8°C) of the product's flash point.
TANK MIXING EQUIPMENT

➧ Procedures and guidelines for tank mixer designs are covered in DP XIII-A and -B, and in APPENDIX A. The following
information is supplemental to the above guidelines.
1. Jet mixing nozzles should be provided with a block valve and valved bypass to a low inlet nozzle that is used when tank level
is low. The use of jet mixers with lightweight floating covers is not recommended due to potential impingement problems;
where mixing is required, propeller type agitators should be used.
2. Propeller Type Agitators
a. Tank agitators must be capable of blending the components of the tank in not more than 24 hours, such that the specific
gravities of top, middle, and bottom samples do not differ from each other by more than 0.0015. The exact blending
time should be set to match operating requirements.
b. The vendor must recommend the number, motor specifications, shaft size, impeller size, and locations of the tank
agitators to accomplish the operation. Final acceptance will be based on Owner's approval.
Minimum HP per volume criteria to achieve various mixing objectives is covered in DP XIII-B.
Commercial mixer sizes are limited to 75 HP (56 kW); therefore, multiple mixers are required for large tanks to provide
the necessary mixing energy.
c. Motor, gear, and shaft seal must be removable while the tank is in service.
d. Because slopping will result in the most severe mixing duty for crude tanks, the slop inlet line will be considered as the
fill line for the purpose of locating crude tank agitators. The product inlet line will be considered the fill line on all other
tanks.

ENGINEERING Date

e. Agitators for crude tanks must be designed to avoid deposition of wax on the tank side walls and bottom.
f. Agitators in floating roof tanks must be mounted at minimum elevation above the tank shell base line. Roof recesses
may be specified to accommodate the full circle of rotation of the agitator propeller.
g. Local start-stop switches must be provided.
h. Agitators must be equipped with low level cut-offs utilizing the automatic tank gauge, which will turn off the agitators
when the liquid level drops. Location of the cut-off above the agitator circle of rotation must be adjustable from 1 to 5 ft
(0.3 to 1.5 m). When used with floating covers, the agitators should not be operated when the cover is floating less than
5 ft (1.5 m) above the agitators.
In certain locations, sludge accumulation in crude tanks is a significant problem. Sludge, especially from waxy crudes, can build
up, often unevenly and interfere with floating roof travel. The volumes of accumulated sludge have shown a primary correlation
with mixer power. Secondary factors are use of swivel mixers and mixer arrangement especially for tanks where underpowered
mixers are installed. Swivel angle mixers tend to reduce sludge build-up. Similarly, distributed mixers instead of a clustered
mixer arrangement reduce the height of sludge accumulation. Further details on the result of sludge experiences in the
European circuit and recommendations of the use of mixers can be found in ER&E Report No. EE.18E.86, Crude Tank Mixing
and Sludge Control Guide.
TANK GAUGING EQUIPMENT

1. All tanks shall be provided with a minimum of one automatic level gauging instrument per tank, readable locally from grade
at the tank base, and remotely if required. Gauge glasses are prohibited on storage tanks.
➧ 2. All level gauging and associated temperature measuring devices to be installed on new or existing storage tanks shall be
designed to meet the requirements of the applicable Hydrocarbon Measurement Practices or best practices where practical.
If this is not economically justifiable, the installation should match existing equipment.
➧ 3. Automatic level gauging Instruments shall be radar, servo-operated, or float type. HTG type may be used in certain specific
applications (see note and comments below). Automatic tank gauge selection shall be based on the following criteria:
\
APPLICATION GAUGE TYPE
Sales, Custody-Transfer by Volume Radar, Servo-operated

Internal Inventory Accounting by Volume Radar, Servo-operated, Float, HTG (1)
Mass Accounting Radar, Servo-operated, HTG (1)
Note: (1) Prior to selecting hydrostatic tank gauging (HTG) for use in internal inventory
accounting by volume applications, its susceptibility to product density
stratification should be evaluated against the product to be measured.
4. Automatic level gauges (Radar, Servo-operated, Float) shall be capable of measuring level to ± 1/8 in. (± 3 mm). For
custody transfer applications local authorities may require greater accuracy than this for the entire gauging system (i.e., level
gauge, signal transmission, and data acquisition system). Consult with the local customs authorities. Float type level
gauges can require a relatively large amount of maintenance, compared to other types of tank gauging, to achieve and
maintain their quoted level accuracy.
➧ 5. Hydrostatic type instruments shall be capable of measuring level to ± 1 in. (± 25 mm). The primary advantage of this
technology is its ability to measure product mass. However, it is recognized that the majority of custody transfers are still
being done on a standard volume basis, for which HTG may require specific approval by local customs authorities, and
specific exceptions from Hydrocarbon Measurement Practices.
6. A stilling well is required for all tanks with internal level gauging devices if the tank is equipped with agitators or jet nozzles,
or if the tank gauge is used for custody transfers. The use of a stilling well is recommended for all new installations because
equipment maintenance and adjustments are decreased while overall gauge performance is improved. Note that HTG does
not utilize a stilling well and therefore accurate measurements are difficult in tanks where mixing is occurring.
7. All tanks require provisions for manual gauging in addition to the automatic tank gauges described above. A slotted
combination manual gauging and sample well with hatch shall be provided for this purpose, and shall be located near the
automatic tank gauge.

Date ENGINEERING
8. When new gauging facilities are being implemented on atmospheric storage tanks that will be remotely monitored, an
independent high-level alarm switch shall be provided. The high level switch shall be physically separate from, and shall
operate independently of, the automatic tank gauging system. Facilities shall be provided for on-line testing of this switch
using the fluid in the tank. The high level switch shall be set to allow personnel sufficient time to stop flow without exceeding
the permissible filling height of the tank. Alarms shall be located so they are audible to personnel controlling the tank filling.
9. An emergency high liquid level alarm shall be provided on each atmospheric storage tank that handles material with a flash
point of 100°F (38°C) or lower. The requirements for the level switch and alarm are the same as those outlined in the
previous paragraph.
➧ 10. The specific design and installation requirements for automatic tank gauging instruments, and any related temperature
measurement elements will depend on the type and style of equipment selected, and the style of the storage tank. Refer to
the International Practices and API MPMS 3.1B for these requirements along with detailed installation and orientation
sketches.
TANK HEATERS
1. See Section XVI, Thermal Insulation, for determining tank heating requirements. Helpful information is also available in
vendor catalogues such as Brown Fintube.
➧ 2. The heaters should be designed so that the heating surface is never exposed during operation over the normal working
range of the tank liquid level. Exposed heating surface above the liquid level may promote the formation, and contribute to
the ignition, of pyrophoric materials. However, an independent vertically oriented hairpin loop should be provided if the
heater is used to remelt a product, to provide adequate expansion for liquid trapped underneath a solid surface. This is
applicable in, for example, asphalt tanks service where the product is allowed to solidify during the winter season. See
Reference # 25 for further details.
3. There must be no interference between the floating roof and the tank heaters when the roof is in the lowest landed position.
INLET DISTRIBUTORS FOR INTERNAL FLOATING ROOF (IFR) TANKS

➧ Initial filling rates for tanks with light weight IFRs should be limited to an inlet velocity of 3 ft/sec (1 m/sec) until the IFR is floating
approximately 10 ft (3 m) above the liquid inlet. This is to prevent IFR instability and or sinking due to turbulence and to allow air
venting during initial flotation. It is recommended that inlet diffuser nozzles of the type shown in Figure 9 or a flush-type nozzle
be used with internal floating covers to ensure maximum protection against turbulence and instability resulting from high inlet
velocities. Diffuser nozzles may be installed on the tank floor as shown in Figure 3 or slightly above the floor as shown in Figure
9. Installation above the floor provides clearance for inspection of tank floor and application of floor coating if required. External
floating roof (EFR) designs are more robust and heavier. Consequently, inlet velocity is not a problem for an EFR once the roof
is fully floating.
MINIMIZING TANK INVENTORY

The following design features should be incorporated in tank designs to minimize non-withdrawable inventory (tank innage).
These are covered in more detail in ER&E Report No. EE.1M.86, Guidelines for Minimizing Nonwithdrawable Tank Inventory. If
designed with these features, better tank utilization will result, and the innage height as shown earlier in this section can be
reduced depending on the tank type and nozzle configuration.
For fixed roof tanks, vortexing and subsequent loss of pump suction are the main limitations while operating at low levels. See
Figure 10. Low minimum operating levels can be achieved by using: 1) API low elbow down nozzles, 2) slotted suction nozzles
which split flow and reduce inlet velocity (recommended in lieu of elbow down nozzles where drawing off directly from the tank
bottom must be avoided), or 3) multiple suction nozzles of smaller size.
Heaters are another limitation on minimum operating level. To permit operation of heaters at minimum levels, flat form fin tube
heaters are recommended for clean products and horizontal coils of bare pipe type heaters are recommended for residual fuels
or asphalt. In either case, a minimum liquid cover of at least 6 in. should always be maintained. Two thermowell locations are
recommended: one at the 5 ft 6 in. (1.7 m) level for normal temperature sensing and another at a lower level to be used only
when the tank level drops below the primary thermowell.
Tank mixers also require minimum submergence. Neither the propeller mixer nor the jet stream from a jet mixer must break the
surface. Automatic low level cutouts are recommended for the propeller mixers. Jet nozzles should be provided with a block
valve and valved bypass to a lower normal inlet nozzle.

ENGINEERING Date

For floating roof tanks - especially those in crude service, the use of flush-type nozzles for suction and fill lines 12 in. (300 mm)
and larger is recommended to enable maximum roof travel; API low nozzles should be used for suction and fill lines smaller than
12 in. (300 mm). The floating roof and roof drain should then be designed to permit the outer pontoon to reach a point within 15
in. (375 mm) of the tank bottom. The same considerations given above for fixed roof tanks apply to the use of mixers.
Additionally, for propeller mixers, the floating roof can be provided with a cutout to house the propeller and enable lower roof
travel.
Remote tank level instrumentation and remote-operated valves should be considered for all new tanks to facilitate regular
operation down to the target minimum normal operating levels.
TANK BOTTOMS AND LEAK DETECTION

There are a growing number of secondary containment/leak detection systems in use by Exxon and other major energy
companies today. Most of these designs are based on a double-bottom steel tank or a single bottom steel tank underlain with an
impermeable membrane. The latter is used within Exxon and other oil companies for new construction. The two recommended
designs are discussed below.
➧ At the request of the Exxon Company U.S.A. Marketing Department, ER&E prepared a double bottom steel tank secondary
containment design as pictured in Figure 11 for tank revamps. With secondary containment, the existing steel bottom is repaired
as described in the Tank Maintenance Guide. It is lined internally with a semi-bonded glass reinforced plastic (GRP) liner, which
is the containment membrane. It is totally bonded around the juncture of the existing bottom plate and remaining shell plate.
However, it is applied to a brush blasted surface over the remaining bottom. Prior to the installation of the new tank bottom, 4 in.
of oiled sand or 4 in. of dry sand and sacrificial anode cathodic protection system are applied to the existing bottom as a
corrosion preventive measure. The new bottom is installed, and it is internally lined to prevent internal corrosion from the stored
product. Telltale pipes are installed in the interstitial spaces between the existing and the new bottoms. In the event of a leak
from the bottom of the storage tank, the stored hydrocarbons will be channeled and visibly detected when emitted through the
telltale pipes. Cathodic protection is required to protect the existing tank bottom if soil side corrosion is a problem.
One advantage to this design is that is has been used for years to repair many storage tanks within the Exxon circuit. The new
technology involved is the installation of the telltale pipes and the semi-bonded GRP liner. It is expected that this economical
design will give many years of corrosion free service, i.e., leak free service.
The use of impermeable membranes beneath new tank bottoms has been recommended and is specified in IP 4-8-1, Tank
Foundations. It is particularly suited for new tank installations and unsuitable for existing storage tanks. The design is pictured in
Figure 12. As shown, a new storage tank bottom is constructed over a 2 in. thick oiled sand pad underlain by 4 in. of finely
crushed stone. Note that IP 4-8-1 provides some flexibility in selecting the sand/stone material. Beneath that is the impermeable
leak detection membrane. This is fabricated from a high-density polyethylene welded sheet construction. A metallic or plastic
sump for water drainage or detection of a hydrocarbon leak from the storage tank is located near the center of the tank bottom. It
is connected to the outside of the tank foundation by a telltale leak detection pipe. This design, although available for a number
of years, has not been frequently used. The first large-scale installations have recently been made.
SECONDARY CONTAINMENT
➧ There remains the risk of polluting ground water following a spill in tank farms due to soil permeability. Laws in some states now
require the installation of an impervious barrier to cover the tank pit area if natural soils are not sufficiently impervious. ER&E
Report No. EE.30E.92 covers methods of reducing permeability of tank dikes and pits. One method of using a HDPE liner of
welded seam construction is shown in Figure 13. This design was prepared for a new tank installation at the Memphis Terminal.
Note that 80 mils is now recommended as the minimum thickness of the HDPE liner. Caution: The liner material shall be capable
of containing the stored product - this is mainly a concern with aromatic type products or if the product is hot.
Where HDPE pit liners are used, the entire rainwater runoff will need to be handled since percolation through the soil is no longer
possible. Therefore, larger collection and treating systems for run-off will be required.
SPECIAL TANK SERVICES

Certain tank services require special consideration because of their unique operating characteristics. These services are: (a) hot
tanks, (b) slop tanks, (c) ballast water tanks, (d) liquid sulfur tanks, and (e) acid tanks. A brief description of each is given below.
Hot Tanks - Operating temperatures near or above the boiling point of water represent a hazardous condition in any atmospheric
tank. Any water introduced into a tank and raised to boiling point will cause violent frothing and venting as it vaporizes, even
causing rupture of the weak roof seam and a boilover of the tank contents. Light hydrocarbons introduced into hot tankage can
have a similar effect.

Date ENGINEERING

To minimize this hazard, tanks must not be operated within certain temperature ranges. The lower end of this range has been set
at 200°F (93°C) to allow for a margin of safety before the boiling point of water is reached. The upper end of this range depends
on the height of the product in the tank, since the boiling point of water increases with an increase of pressure. For example,
water in a tank bottom will start to boil at 250°F (122°C), rather than 212°F (100°C), when the total static product head above the
water is 35 ft (10.5 m). For this reason, tanks with a total height up to 35 ft (10.5 m) (height includes the cone down bottom) must
be operated either below 200°F (93°C) or above 265°F (130°C) [250°F (122°C) plus 15°F (8°C) for safety margin due to
temperature gradients in hot tanks. See ER&E Report No. EE.85E.83.]
➧ As a result, tanks must be either designated for “cold" service with design and operating controls to prevent temperatures from
exceeding 200°F (93°C), or classified as “hot" tanks operating above 265°F (130°C) for tanks up to 35 ft high (10.5 m), plus 0.7°F
per ft (1.3°C per m) for higher tanks. This data is based on a liquid with a gravity of 10API degrees at 60°F (1000 kg/m3 at 15°C)
at sea level. Safe temperature ranges for liquids with different gravities must be adjusted accordingly. For locations at high
elevations, the reduced atmospheric pressure should also be taken into account when determining the safe temperature range.
Air blowing for line clearing or tank mixing can create flammable vapors. Intimate air contact with asphalt results in an
exothermic oxidation. This reaction starts at about 400°F (200°C) and accelerates as the temperature increases eventually
reaching its ignition temperature. Therefore, where air is used for tank mixing, procedures must ensure that the tank temperature
of 400°F (200°C) is not reached during the blowing period. Air blowing of asphalt lines should be permitted only when they have
cooled below 400°F (200°C). Air blowing should be controlled to prevent flow of large air quantities into a tank after clearing
asphalt from the piping. The air speed should be limited to 20 ft/s (6 m/s) at the tank inlet nozzle. A restriction orifice should be
used in the line to prevent excessive blowing. Cutback asphalt lines must not be airblown unless there is 6 ft (1.8 m) of liquid
covering the tank inlet nozzle.
➧ “Hot" tanks are subject to the following design and operating requirements (see Section XV-B and Reference # 25 for
recommendations specific to asphalt operations):
1. Large hot tanks [diameter over 100 ft (30 m)] should have at least four temperature indicating points at the 1 ft (0.3 m) level
above the tank bottom, spaced 90° intervals around the circumference, and four TI points at the 10 to 12 ft (3 to 3.7 m) level
staggered at 45° between the lower TI points. The TI points should be 3 to 4 ft (0.9 to 1.2 m) in from the tank shell. To
ensure that actual operating temperatures do not fall below 250°F (122°C), the observed temperature must be held above
265°F (130°C) for tanks up to 35 ft (10.5 m) high [plus 0.7°F (1.3°C per m) per ft for higher tanks]. For tanks under 100 ft
(30 m) in diameter, at least two TI points at the 1 ft (0.3 m) level and two TI points at the 10 to 12 ft (3 to 3.7 m) level should
be provided.
2. The above minimum temperature restrictions apply to streams entering the tank as well as to the bulk temperature within the
tank.
3. Tank mixers may be used to reduce temperature variations throughout the tank contents. Use of air for mixing is not
recommended for new designs.
4. Adequate controls or procedures must be established so that “cold" storage tank temperatures will not exceed 200°F (93°C),
or so that “hot" tanks will not cool down below 265°F (130°C), for tanks up to 35 ft (10.5 m) high, plus 0.7°F per ft (1.3°C per
m) for higher tanks.
5. Stream rundown temperatures must be limited to the bulk holding temperatures of the tanks. Without inerting, the bulk
holding temperatures should be limited to 450°F (232°C). Higher temperatures [up to 500°F (260°C)] may be used if the
tanks are inerted to avoid auto-ignition and the tank is specified to be designed to API 650, Appendix M.
6. Hot tanks should be of the fixed roof - cone bottom down type, with the water drawoff connection at the center (for startup
purposes). However, sulfur storage tanks should be of the fixed roof - cone bottom up type.
7. Tank drawoff nozzles should be located at the lowest practical level, to keep the bottom hot and moving. The filling
connection should also be located as close to the bottom as practical. Once in service, hot tankage used for feed should be
maintained with a hot inventory of about 6 ft (1.8 m) in order to keep the bottom thermally expanded. Otherwise, rapid filling
with hot material before the tank floor is expanded could damage the tank floor.
8. Hot oil coils, steam coils (all welded type only) and direct-fired heaters are acceptable methods for heating “hot" tanks. Hot
oil coils are preferred for safety reasons; however, because of the additional investment for a hot oil furnace, hot oil storage
vessel and circulation system, this method may not be economically feasible where a small number of tanks are involved.
All heater coils should be designed so that they are not exposed during normal operation of the tank. However, a heater
cutout set at least 6 in. (150 mm) above the coils should be provided on heaters with maximum coil temperatures of 350°F
(175°C) or above to avoid possible ignition by hot exposed surfaces. This precaution is not necessary with steam if the
maximum steam temperature is below 350°F.
Tank temperature can also be maintained using a slipstream of hot material rundown from the unit. In this case, an
emergency or backup heater or coil is also required.

ENGINEERING Date

➧ An independent vertically oriented hairpin loop should be provided if a tank heater coil is used to remelt a product, to provide
adequate expansion for liquid trapped underneath a solid surface. This is applicable in, for example, asphalt tanks service
where the product is allowed to solidify during the winter season. See also Reference # 25.
9. Heat exchangers on plant streams routed to hot tanks should be designed so that the stream going into the hot tank is at the
higher pressure. This is to prevent the possibility of contamination by water or light hydrocarbon in case of a tube leak.
10. The possibility of water or light hydrocarbon streams being routed to hot tanks must be eliminated. In addition to adequate
operating and startup procedures, piping systems upstream of hot tanks should be simple and free of connections, which
could result in the wrong material entering the tank. For example, rundown lines containing heavy material are sometimes
provided with flushing connections. The choice of flushing material is extremely important since the entry of even small
amounts of low boiling point material into a hot tank will generally exceed the venting capacity of the tank.
11. Roof fittings should be watertight. The tank should be provided with a weak roof seam.
12. Splash filling in hot tanks should be avoided to prevent electrostatic ignitions.
13. Heavy residuum feed, normally fed directly to downstream units such as a coker may require the use of an intermediate tank
to cover upsets or outages. Since this feed has not been desulfurized and often contains nitrogen compounds, the vapor
space of the tanks storing this stock contains compounds that are pyrophoric and have a very bad smell. Therefore, some
sort of vapor control with blanketing of the tank is usually employed.
Slop Tanks - Slop storage facilities are classified into three basic categories: (a) light ends slop, (b) light atmospheric slop, and
(c) heavy atmospheric slop. Light atmospheric slop is further categorized into leaded and unleaded slop at refineries where
leaded mogas is still produced. Positive segregation must be maintained among the three systems. These three types of slop
and their storage requirements are described below.
1. Light Ends Slop - This classification covers slop materials, which have a true vapor pressure greater than 13 psia (90 kPa
absolute) at rundown or storage temperature. Pentane and lighter hydrocarbons normally fall within this range. Pressure
storage is required unless alternative methods are used to handle or dispose of the slop. Some of these methods are:
a. Vaporizing to a flare via a blowdown drum.
b. Weathering to a flare via a blowdown drum until the vapor pressure is low enough for storage in the light atmospheric
slop system.
c. Routing to rerun facilities.
d. Blending into heavier streams for storage in an atmospheric system. Controls must be provided to prevent the pressure
in the blend tank from exceeding 13 psia (90 kPa absolute) at the storage temperature.
2. Light Atmospheric Slop - This classification covers slop materials which have a true vapor pressure of 13 psia (90 kPa
absolute) or less at tank rundown or storage temperature, and which do not require heating for emulsion breaking. Such
materials would cause severe gas emission if stored in a heated tank. Products, which normally fall in this class, are
naphthas, kerosenes and jet fuels. Light atmospheric slop must be stored in a floating roof tank without tank heaters.
Leaded slop from mogas operations is segregated from all other slops to avoid poisoning of process unit catalysts while the
slop is being rerun. Leaded slop can be disposed of as feed to a Combo Tower or by blending into final products.
3. Heavy Atmospheric Slop - This classification covers those slop materials which may require heating for emulsion breaking,
but which will not have a true vapor pressure higher than 13 psia (90 kPa absolute) at the maximum design temperature of
200°F (93°C). Gas oil and fuel oil are examples of heavy atmospheric slop. The following requirements apply for the
storage of heavy atmospheric slop:
a. A fixed roof tank should be used, except where there is a potential for the formation of pyrophoric materials or where,
because of storage conditions, the slop falls within the range for which a floating roof tank is required. Check for this by
referring to SELECTION OF THE TYPE OF ATMOSPHERIC TANK earlier in this section.
b. The tank heaters must be designed so that the heating surface is always covered during normal operation.
c. The maximum tank and stream entry temperatures must be restricted to 180°F (82°C).
d. Remote tank temperature indicators should be provided at the appropriate control room, as well as the necessary
instrumentation to ensure safe operating conditions considering the location and manning situation.

Date ENGINEERING

Ballast Water Tankage - For safety reasons, ballast water tanks must be designed in accordance with the properties of the
hydrocarbon present in the ballast water. These hydrocarbons will separate from the water and form a top layer in the tank.
Thus, ballast water which originates solely from ships' bunker fuel spaces must be treated as a petroleum hydrocarbon of the
bunker fuel properties (if known), for the purpose of safety considerations in the design of the ballast water tank. However, if the
ballast water contains a variety of entrained hydrocarbons from ships' cargo spaces, then the ballast water tank must be
designed for a low-flash product.
Liquid Sulfur Tankage - Molten sulfur is stored in a conventional cone roof tank with a cone up bottom.
Tank Heating - Molten sulfur has a narrow operating temperature range of 270°F to 290°F (130°C to 150°C) since it solidifies at
238°F (114°C) and becomes very viscous above 320°F (160°C). Therefore, sulfur tanks are well insulated, typically 3-4 in.
(70-100 mm) of mineral wool with aluminum jacketing. Liquid sulfur tanks should be provided with floor heating coils having
100% spare capacity. In addition, the roof is heat traced and insulated. Heating coils are usually 1 1/2 in. (40 mm) diameter
schedule 80 steel pipe with all welded connections. 50-60 psig (350-415 kPa gauge) saturated steam is used for this service to
prevent overheating the sulfur.
Venting - Venting of the tank is based on 1 ft2 of vent area for every 1000 ft2 of tank wall surface area (1 m2 vent area/1000 m2
tank wall area). Vents are typically 8 to 12 in. (200 to 300 mm) in diameter and arranged with one center vent and several
peripheral vents on the roof. The vents are steam-jacketed and have non-closeable weather caps.
Snuffing Steam - Snuffing steam piping is required for the tank. A frangible disk or other means should be provided to prevent
steam from leaking into the tank when it is not needed. Verify that the maximum steam rate possible through the snuffing steam
line can be relieved by the tank vents without overpressurizing the tank. The snuffing steam line must be well trapped to
preclude sending condensate into the tank.
Miscellaneous - Provide two separate level gauging instruments and temperature high alarms on both the roof and for the bulk
liquid. Provide remote high and low level alarms as well as a local high level alarm. Differential pressure bubble type level
gauges are often used.
Use plug valves in molten sulfur service.
Acid Tankage - When the necessary storage volume for an acid makes storage in drums impractical, it will be necessary to
utilize a cone roof type atmospheric storage tank. Acid tanks have special requirements as covered in IP 9-4-1. These
requirements include the use of special linings and materials and mechanical details. In addition, the use of a toe wall and a
limestone neutralization pit is recommended.
ENVIRONMENTAL CONSIDERATIONS IN TANKAGE DESIGN
WATER EMISSIONS
Tanks receive water from a number of sources and this water, after withdrawal, represents a significant load to the wastewater
treatment and refinery slop water systems. Recent reports by Exxon USA refineries indicate that 13% of the total benzene load
on the wastewater treatment plants come from contaminated tank water drawoffs. The facilities for removing water from tankage
were described previously. Proper design of these systems is necessary to achieve minimum cost implementation of
environmental regulations.
SLUDGE AND SOLIDS EMISSIONS

Over time, solids tend to build up in tank bottoms - especially in crude tanks. Disposal of these solids is quite costly. Proper
sizing and placement of mixers in tanks will minimize the buildup. Mixer selection considerations have been covered previously.
AIR EMISSIONS
Atmospheric tankage is one of the larger sources of organic emissions in a refinery or chemical plant. Tankage typically
accounts for 10 to 30% of a plant's organic emissions to the air. The percentage is very site specific and depends on many
factors including the material stored, the types and conditions of the tanks and their seals, and the presence of emission controls
on other sources. In general, fundamental decisions made for safety reasons, such as storing Mogas in floating roof tanks, are
consistent with environmental and material loss objectives. Detail decisions regarding emission controls systems, such as
installing secondary seals on floating roof tanks, are often driven more by regulatory mandates than material loss concerns.
The trend is for stricter regulations both in mandated equipment control measures and percent reduction requirements. The US
EPA and many states have passed regulations requiring secondary seals on new or modified floating roof tanks. The emission
regulations may be tightened further by requiring that all roof fittings on floating roofs be gasketted and bolted and that internal
floaters have both primary and secondary seals or the equivalent. In Germany, future regulations may be so restrictive that
mogas loading and storage may require vapor-balanced loading, and cone roof tanks with vapor recovery.

ENGINEERING Date
ENVIRONMENTAL CONSIDERATIONS IN TANKAGE DESIGN (Cont)
TYPES OF VAPOR EMISSION LOSSES

Atmospheric storage tank vapor emissions can be broken down into two major categories: 1) Standing losses which occur
without tank level changes and depend on the tank environment and thermal breathing, and 2) Working losses which occur
during the filling and emptying of the tank and are dependent on throughput.
The majority of air emissions (roughly 90%) from an external floating roof tank are usually standing losses. Emission control
efforts are directed towards keeping the wind away from the primary roof seal and eliminating the saturated vapor space between
the seal and liquid surface. Most of the losses from internal floating roof tanks are standing losses as well but stem primarily from
thermal breathing; the roof eliminates most of the wind effects within the tank itself. The losses from internal floating roof tanks
also include diffusion through the rim seals and deck fittings of the floating roof as well as evaporation of material clinging to the
tank wall upon product removal. Most of the losses from fixed roof tanks without internal floating roof are working losses.
CONTROLS TO REDUCE AIR EMISSIONS FROM ATMOSPHERIC STORAGE TANKS

➧ ER&E Report No. EE.35E.93, Selection Guide for Storage Tank Emission Controls, provides guidance for the selection of air
emission control systems for new and existing atmospheric storage tanks. EPA Publication AP-42 (Based on API work, see
References # 22 and 26) provides calculation methods for estimating evaporation loss from fixed roof and internal roof tanks.
The EPA calculation procedure governs in the US and at a number of other locations. If no information is available as to
calculation procedure for a location, the EPA procedures can be used as a first estimate. This DP section describes the selection
of types of floating roof seals and their attributes. In addition, data from ER&E Report No. EE.35E.93 is presented to compare
cost effectiveness of and relative emissions for various control measures.
Reducing air emissions is part of an overall control strategy. Basic steps in selection of tank emissions controls involve:
1. Identify the emission regulations that apply to facility tankage.
2. Generate a database of existing tank services. Include stored material properties, tank characteristics, and existing
control measures.
3. Estimate current emissions from each storage tank to identify main contributors and provide a basis for potential
reductions.
4. Calculate emission reductions and cost effectiveness of potential control solutions.
5. Recalculate emissions with selected controls in place to assure compliance with identified emission regulations.
SELECTION OF CORRECT TANK ROOF

The selection of the type of tank roof to be used (fixed, external floating or internal floating) depends on a number of factors such
as safety as highlighted previously in this section. The type of tank roof is also a major factor for vapor emissions from the tanks
all other things being equal. Stringent hydrocarbon emission requirements may affect the choice of tank roof and the type and
number of floating roof seals.
A geodesic dome may be added to an existing external floating roof tank and in some cases can be done with the tank in service.
A dome roof eliminates the wind effects on the primary seal. However, it is very expensive and upgrading the primary rim seals
and adding secondary seals achieve similar air emission reductions at a fraction of the cost. A significant advantage for the
domes, however, is that they can prevent rainwater infiltration into the tank. Dome roofs have been justified on benzene-
contaminated water source reduction. In addition, dome roofs are increasingly used to preserve product quality in Marketing
terminals and eliminate snow/freezing water problems in very cold climates. In new tank construction, a geodesic dome/internal
floater combination can be cost competitive with an external floating roof design in some situations.
An existing fixed roof tank can be converted to an internal floating roof tank; however, this may require the tank to be taken out of
service and may reduce tank utilization due to increased outage. Both these options, adding a geodesic dome or an internal
floating roof, while reducing emissions significantly, are very expensive. Typically, conversion to internal floating roof tank
configuration has been done to convert a fixed roof tank to store a high vapor pressure material or to eliminate snow/rain
problems for an external floating roof tank.
FLOATING ROOF SEAL SELECTION

Controlling rim losses in external floating roof tanks is most cost effectively handled by proper seal selection. Different types of
seals are available and vendors offer a wide selection of proprietary designs. Almost all designs fall into three major categories
of primary seals (vapor-mounted, liquid-mounted, and mechanical shoe) and two categories of secondary or auxiliary seals
(“wiper" type and shoe-mounted). Note: mechanical shoe seals are also known as metallic seals.

Date ENGINEERING

Factors to consider in upgrading tank seals include oil losses, maintenance, expected life and mechanical condition of tank shell
(out of roundness), environmental considerations, tank availability, possible loss of tank capacity, and possible change in future
tank service in addition to the material and installation costs. If a new or replacement seal can be installed without the need to
clean and gas-free the tank, it would offer a significant advantage over one that would require taking the tank out of service.
➧ External floating roofs are typically equipped with a mechanical shoe type and an additional secondary seal in highly volatile
hydrocarbon service, for example for mogas tanks. Internal floating roof have typically been equipped with a mechanical shoe
type, and, if required in highly volatile hydrocarbon service, with a vapor mounted resilient foam seal as the secondary seal.
These seals and other types are further discussed below.
PRIMARY RIM SEALS

The function of the primary seal is to separate the stored liquid from the atmosphere by sealing the gap between the floating roof
and the tank shell.
Vapor-mounted seals (Figures 14 c and d) are characterized by a flexible fabric covered sealing “log" which can be foam or gas
filled. The seal is mounted above the liquid level leaving a vapor space between the bottom of the seal and the liquid.
Liquid-mounted seals (Figure 14 b) are similar to the vapor-mounted seal except that the bottom of the seal is in contact with the
product. The liquid-mounted seal is more effective in minimizing emissions than is the vapor-mounted seal.
Mechanical shoe seals (Figure 14 a) are a third type of primary seal commonly used in petroleum service. This type of seal is
characterized by a movable metal plate, which is pressed against the tank wall and supports a sealing fabric between the shoe
and the floating roof. Its effectiveness in minimizing emissions lies between the vapor- and liquid-seal effectiveness. Because of
its large contact area, the mechanical shoe seal is more tolerant of sizeable gaps than are the other types.
Mechanical shoe seals, while the most expensive of the three primary seal types, may be selected for any of the following
reasons:
• When combined with a secondary seal, the combination provides emissions control comparable to any primary/secondary
seal combination for an external floating roof tank.
• They offer a longer service life that may justify the additional expense.
• They are not damaged by tank shell burrs, weld splatter, or non-flush welds as resilient seals are. Therefore, they are
usable with less attention to surface condition.
• No waste disposal problem results from seal replacement.
• Riveted tanks damage resilient seals making mechanical shoes the only viable choice for non-welded tank service.
Vapor-mounted seals have been preferred over liquid-mounted seals in the past because of longer service life, ease of
installation, and lower installed cost. However, improvements in fabric life have increased the life of liquid-mounted seals. Foam
filled liquid mounted seals are susceptible to contamination by hydrocarbons due to leaks in the protective fabric. This presents a
waste disposal problem when seals are replaced and can make gas freeing the tank extremely difficult.
SECONDARY SEALS
Secondary seals are continuous flexible rubber or metal seals that span the gap between the tank wall and the floating roof
above the primary seal. They are usually of the “wiper" type (Figure 15) meaning that they are relatively thin compared to their
width and are held against the tank wall by the force of their flexing. Most secondary seals are mounted on the rim of the floating
roof and are called rim seals. Another type is mounted on the top edge of a mechanical shoe primary seal extending to the tank
wall; this is called a shoe-mounted seal. Rim seals are much more effective than shoe mounted seals in controlling emissions.
Shoe-mounted seals are not acceptable under current US EPA regulations and are no longer offered by many vendors.
Overlapping leaf type weather shields have been used but are not as effective at reducing emissions as continuous secondary
seals.
The main function of the secondary seal is to keep the wind away from the primary seal. The secondary seal also has the benefit
of keeping sunlight and some of the rain away from the primary seal. This reduces degradation of the primary seal fabrics and
the amount of water entering the tank. It also reduces the risk of an annular rim fire.
➧ Dual seals where both seals are of the wiper type are no longer recommended for new installations.
➧ CONTROLLING EMISSIONS FROM ROOF FITTINGS

For typical floating roof tanks, over half the air emissions are through the deck fittings because perimeter seal losses are low with
modern type seals. The largest contributors to emissions are the (slotted) guidepole/sample pipe, roof legs, ladder well, and
internal column wells.

ENGINEERING Date

A slotted guidepole/sample well is responsible for almost all of the total air emissions due to tank fittings for external floating roof
tanks. Using an unslotted guidepole with a gasketted cover will nearly eliminate emissions from this source, however, it would
prevent the use of the guidepole for gauging and sampling. Control alternatives for slotted guidepoles have been developed.
The most cost effective is currently a design utilizing a sleeve without a float. The roof fittings other than the guidepole do not
contribute a significant amount to the emissions from external floating roof tanks.
An effective control for the roof support column fittings for an internal floating roof is a flexible fabric sleeve which attaches to the
floating roof and the top of the column providing a vapor barrier around each column. Again, the controls available for these
sources primarily involve gasketting and seal improvement to restrict diffusion.
COST EFFECTIVENESS OF CONTROL OPTIONS

➧ The following paragraphs discuss various cost effective options for external floating roof tanks and fixed roof tanks.
External Floating Roof Tanks - For new installations of floating roof tanks, a mechanical shoe seal for primary sealing and a
wiper type secondary seal arrangement provides significant technical advantage. (See table below, which is based on data from
ER&E Report no. EE.35E.93). This arrangement requires a higher first cost to achieve comparable emissions reductions
compared to a liquid mounted sealing system. However, the mechanical shoe seal is more rugged and savings are expected
due to reduced maintenance and potentially longer in-service times. In addition, less hazardous waste is produced when seals
are replaced. Liquid mounted seals can absorb hydrocarbons if the resilient protective fabric fails, thus creating a waste disposal
issue. In addition, it is very difficult to gas free a tank with a failed foam filled liquid mounted seal.
The cost of control options change over time and additional controls may become available. Consequently, the data in Table 1
should be reevaluated at the time of specification. For existing floating roof tanks, the addition of a secondary seal is the most
cost-effective method of significantly reducing vapor emissions. Geodesic domes are one of the more expensive options for
reducing tankage vapor emissions. However, they have been used extensively in marketing terminals primarily to avoid water
infiltration.
Fixed Roof Tanks - As discussed previously, fixed roof tanks should only be used to store low vapor pressure stocks and
generally do not present an attractive opportunity for reducing vapor emissions. Where it is necessary to store a higher vapor
pressure stock such as mogas in a fixed roof tank, an internal floater would be an effective control device. Where odor is a
problem with low vapor pressure material, inert gas blanketing or vapor enrichment are reasonable control options with disposal
to a flare, an incinerator or vapor recovery unit.
➧ SUMMARY OF CONTROL OPTIONS FOR HIGH VAPOR PRESSURE STOCKS

The following control options should be considered for a typical high vapor pressure (4 psia to 13 psia) service. Exceptions may
be acceptable for small volume, special circumstance situations.
1. Store in a floating roof tank. Emissions from a fixed roof tank would be excessive and fire risk would be too high. If
necessary from a tankage allocation standpoint, convert a fixed roof tank and check spacing, fire protection, etc.
2. Consider rim-mounted secondary seals for external floating roof configurations. Secondary seals are required by many local
authorities and have benefits such as improving the life of the primary seal and reducing the risk of rim fires.
3. Consider upgrading primary seal if required during tank turnaround.
4. Consider adding control measures to roof fittings if further reduction required.
5. Consider adding a geodesic dome roof to an existing floating roof tank to reduce the wind effects on the floating roof's seals.
6. Consider vapor balancing; vapor recovery/destruction as a last resort. While producing the best potential reduction, these
steps are very expensive.

Date ENGINEERING
TABLE 1
COMPARATIVE EMISSIONS / COST EFFECTIVENESS FOR TANKAGE CONFIGURATIONS / CONTROL OPTIONS
REFERENCE ER&E REPORT NO. EE.35E.93 DATA

STOCK = MOGAS RVP = 9 psi STORED AT AMBIENT TEMPERATURES
EMISSIONS COST* REDUCTION

BASIC CONFIGURATION COMMENTS TONS/YR 1991 K$ TONS/YR
A. Cone Roof Tank D = 90 ft 780 Base

1. Add vapor balancing 80 Site Specific 700
2. Add vapor recovery/vapor destruction 5 to 80 100 to 1000+ 700 to 775
Note: Vapor recovery efficiency and cost will vary with the specific technology and application.
B. Adding bolted internal floating roof, with vapor D = 90 ft 5 62** 775

mounted primary seal.
Further steps such as secondary seals, gasketting tank fittings provide only marginal emissions reductions since adding the IFR
provided a 99.3% reduction.
C. External Floating Roof Tank D = 210 ft
1. Vapor Mounted
A. Foam Filled Primary Seal 152 Base —
B. Add Rim Mounted Secondary Seal 63 +29 89
2. With Mechanical Shoe
A. Primary Seal Only Compared to Base (Vapor Mounted) 43 +23 109
3. With Liquid Mounted Primary Seal
A. Primary Seal Only Compared to Base (Vapor Mounted) 27 +45 125
4. Add a geodesic dome roof Compared to Base (Vapor Mounted) 2 to 4 +304 ~ 150
Further steps such as gasketting roof fittings are done only if required by local regulations. Using unslotted guide poles defeats
the ability to sample and tank gauge through the hatch on the guide pole.
Notes:
* Cost values are in 1991 Gulf Coast dollars. Excludes “other considerations" such as out of service time, tank cleaning, etc. The cost values
are provided for rough comparison only. Actual costs can vary significantly.
** For IFR only. Does not include the cost of tank cleaning or any required tank modifications that can be extensive.

ENGINEERING Date
➧ DESIGN SPECIFICATION CHECKLIST

The following checklist covers the basic items that should be included for each tank in a tankage specification.
WERE THESE ITEMS SPECIFIED?

• Tank service.
• Tank number.
• Flash class of material.
• Dimensions (diameter and height) and or working capacity.
• Roof type.
• Specific gravity of tank contents, if pontoon-type floating roof.*
• Bottom type.
• Bottom settlement category.
• Type of mixing equipment.
• Maximum inlet and outlet rates.
• Surface area of tank heaters.
• Number and size of nozzles.
• Critical exposure temperature.
• Instrumentation - local and remote.
• Secondary containment features, if any.
• Materials of construction, corrosion allowance, and lining materials, if any.
• Seal type (primary and secondary).
• Emission controls on roof fittings if required.
ARE ALL RUN-DOWN TEMPERATURES AND PRESSURES IN THE SAFE RANGE?

• Less than 13 psia (90 kPa absolute) true vapor pressure.
• Outside the 200°F to 265°F (93°C to 130°C) range.
• Below the autoignition temperature.
• Within local shipping requirements for temperature.
• No hot streams into cold tanks or cold streams into hot tanks.
CHECK THAT THE FOLLOWING ITEMS WERE CONSIDERED

• Flash point.
• RVP (and ambient pressure if tank is located well above sea level).
• Maximum and minimum ambient temperatures, and rain and snow loads for external floating roofs.
• Thermal expansion factors.
• Local laws (especially for air pollution, tank spacing, and fire protection).
• Electrostatic characteristics of the hydrocarbon.
• Local environmental regulations.
* Note: The pontoon volume is specified by API, based on a specific gravity of 0.7. If the liquid to be stored is less dense than
this, additional pontoon volume will have to be provided.

Date ENGINEERING
SAMPLE PROBLEMS
PROBLEM 1 (CUSTOMARY UNITS)

Size crude tankage for a new refinery (Customary Units). Use the “Parcel Size plus Advance and Delay" method.
Given:
• Crude throughput and characteristics:
- B/SD: 60,000
- Density @ 60°F, lb/gal: 7.462
- Pour Point, °F: 10
• Crude will be received in 100 KDWT (Dead Weight Ton) tankers. Typical tankers are not volume limited if cargo SG > 0.75.
For double hull and segregated ballast tankers, refer to shipper.
• Tankers Advance and Delay factors: 1 and 4 days, respectively.
• Two days allowed for tankers unloading, settling, and water drawoff.
• Compulsory requirements: 4% of the annual crude run at the refinery.
• One calendar day throughput = 0.9 stream day throughput.
Find: Determine the tankage required for crude storage.
Solution:
• Determine the gross volume of tankage required for parcel size:
(1 DWT = 2240 lb). (Note: Metric tons are sometimes used instead of long tons.)
2240 lb 1 gal 1 bbl

100 KDWT x x x = 715 kbbl per parcel net requirement at 60°F
DWT 7.462 lb 42 gal
Tank Utilization Factor:

The lowermost and uppermost portions of the floating roof tank cannot be considered usable because of
roof travel limitations, nozzle locations, and safety reasons.
Net Volume = Gross Volume x Utilization Factor
Actual Shell Height − (Innage + Outage )
Utilization Factor =
Actual Shell Height
Actual Shell Height = Limited by Location and Soil Parameters

Innage = Unusable Bottom Portion
Outage = Unusable Top Portion
Crude is low-flash and is stored in floating-roof tanks.
For Floating-Roof Tanks: Innage = 2.5 ft (0.8 m)
Outage = 1.0 ft (0.3 m)
Note: Shell extension to contain floating roof is additional.
Use 48 ft (15 m) as desired height for the purposes of this example.
Note: Shell extension to contain floating roof is additional.
48 − (2.5 + 1.0 )
Utilization Factor = = 0.927
48
15 − (0.8 + 0.3 )
In Metric = = 0.927
15

ENGINEERING Date
SAMPLE PROBLEMS (Cont)

Assuming that the summer storage temperature for the crude can reach a maximum of 110°F, the expansion factor from
Section 8 in the Exxon Blue Book is 1.035 (using a base temperature of 60°F, 200°F average Boiling Point). Alternatively,
use Figure 4.
 1.035 
For a parcel size, gross volume = 715 kbbl x   = 798 kbbl
 0.927 
• Determine the gross volume of tankage required for advance/delay reserve:

Reserve = Throughput (B/SD) x (Advance Days + Delay Days + Pumping and Settling Days)
(Use the same expansion and tank utilization factors determined above.)
bbl  1.035 
Reserve = 60,000 x (1 Day + 4 Days + 2 Days) x   = 469 kbbl
SD  0.927 
• Determine the gross volume of tankage required for compulsory storage.

 SD   CD 
Compulsory = Throughput (B / SD) x   ×  365  (% Requirement / 100)
 CD   YR 
bbl  0.9 SD   CD  1.035

Compulsory = 60,000 x   ×  365  × (0.04 ) × = 880 kbbl
SD  CD   YR  0.927
• Sizing of Tankage
Total gross storage required: 798 kbbl + 469 kbbl + 880 kbbl = 2,147 kbbl
Select number of tanks: Considerations
- Greater number of smaller tanks offers more flexibility but at a greater cost.
- Selecting enough tanks such that a crude parcel can be unloaded in tanks other than the one used to feed the refinery.
- Determine if compulsory storage requirements must be kept in segregated tankage.
- Owner's preference.
For this problem, assume four equal–sized tanks selected.
2,147 kbbl
bbl / Tank = = 536.75 kbbl
4 Tanks
536,750 bbl bbl

Required volume / ft of tank height = = 11,182
48 ft ft
bbl ft 3 4
d2 = 11,182 x 5.614 x = 79,930 ft2
ft bbl π
d = 282.7 ft
Use 283 ft
Actual volume / ft of height = 11,204 bbl/ft
bbl
Actual gross volume = 11,204 x 48 ft = 537,800 bbl
ft
Solution: Provide four, floating roof 538 kbbl tanks 283 ft φ x 48 ft high.

Date ENGINEERING
PROBLEM 1 (METRIC UNITS)

Size crude tankage for a new refinery (Metric example). Use the “Parcel Size plus Advance and Delay" method.
Given:
• Crude throughput and characteristics:
- m3/SD: 10,000
- Density @ 15°C, kg/m3: 895
- Pour Point, °C: -12
• Crude will be received in 100 KDWT (Dead Weight Ton) tankers.
• Tankers Advance and Delay factors: 1 and 4 days, respectively.
• Two days allowed for tankers unloading, settling, and water drawoff.
• Compulsory requirements: 4% of the annual crude run at the refinery.
• One calendar day throughput = 0.9 stream day throughput.
Find: Determine the tankage required for crude storage.
Solution:
• Determine volume of tankage required for parcel size:
1016 kg 1 m3
100 KDWT x x = 113.5 km3 per parcel net requirement at 15°C
KDWT 895 kg
Note: Long tons were used. However, in some markets, Metric tons are the unit of measure.
Tank Utilization Factor = 0.927
(Refer to Customary unit example above.)
Assuming that the summer storage temperature for the crude can reach a maximum of 45°C, the expansion factor from
Section 8 in the Exxon Blue Book is 1.035 (using a base temperature of 15°C). Figure 4 may also be used.
 1.035 
For a parcel size, gross volume = 113.5 km3 ×   = 126.7 km3
 0.927 
• Determine volume of tankage required for advance/delay reserve:

Reserve = Throughput (m3/SD) x (Advance Days + Delay Days + Pumping and Settling Days)
 1.035 
Reserve = (10 km3/SD) x (1 Day + 4 Days + 2 Days) ×   = 78.2 km3
 0.927 
• Determine volume of tankage required for compulsory storage.

 SD   CD   % Re quirement 
Compulsory = Throughput (B / SD) x   x  365  x  
 CD   YR   100 
 0.9 SD   CD  1.035
Compulsory = (10,000 m3/SD) x   ×  365  × (0.04 ) × = 146.7 km3
 CD   YR  0.927

ENGINEERING Date

• Sizing of Tankage
Total gross storage required: 126.7 km3 + 78.2 km3 + 146.7 km3 = 351.6 km3
Select number of tanks: For this problem, assume four equal-sized tanks selected. (Refer to Customary unit example above
for considerations in selection of the number of tanks.)
352 km 3
m3 / Tank = = 88 km3
4 Tanks
Set tank height = 14.6 m (48 ft)
88,000 m 3
Required volume / m of tank height = = 6027 m3/m
14.6 m
4
d2 = 6027 m3/m x = 7674 m2
π
d = 88 m
Solution: Provide four, floating roof 88 km3 tanks 88 m φ x 14.6 m high.
PROBLEM 2
Determine net product tankage volume for heating oil.
Given:
PARAMETER CUSTOMARY UNITS EXAMPLE METRIC EXAMPLE
• Heating oil production rate: 20,000 B/CD @ 60°F 3,200 m3/CD @ 15°C
• Pipestill turnaround time: 8 days 8 days
• Seasonality: 3% 3%
• Maximum product parcel size: 30,000 bbl @ 60°F 4,800 m3 @ 15°C
• Advance / delay / imbalance requirements: 7 days 7 days
• Maximum ambient temperature 100°F 40°C
• Compulsory storage requirements*: None None
* Compulsory storage requirements are set by certain governments as reserves in case of a national emergency.
Solution: (Customary units example)

• Determine net volume of tankage required for working storage:
Net working storage volume = [Annual Production Rate x % of Seasonality] + [Maximum Parcel Size] + [(Advance + Delay) x
Daily Production Rate]
 bbl   bbl 
= 20,000 x 365 CD x 0.03 + 30,000 bbl + 7 CD x 20,000
 CD   CD 
= 389,000 bbls at 60°F

Expansion factor for volume correction = 1.019 from 60°F to 100°F (Exxon Blue Book) or refer to Figure 4.
Required Net Working Storage = 389,000 bbl x 1.019 = 396,000 bbl

Date ENGINEERING

• Determine net volume of tankage required for turnaround protection:
Net Volume for Turnaround = Daily Production Rate x Turnaround Days
bbl
= 20,000 x 8 CD = 160,000 bbl at 60°F
ft
or = 163,000 bbl at 100°F

This requirement is much smaller than that for working storage. It is reasonable to assume that the pipestill turnaround can
be scheduled so that it does not occur during the peak heating oil season. Thus, only the working storage volume will be
used.
Result:
Net Volume Required for Heating Oil Storage = 396,000 bbl
(Heating oil is normally stored in cone roof tanks. Refer to PROBLEM 1 to determine the actual tank gross volume and
dimensions.)
Solution: (Metric example)

• Determine net volume of tankage required for working storage:
Net working storage volume = [Annual Production Rate x % of Seasonality] + [Maximum Parcel Size] +
[(Advance + Delay) x [Daily Production Rate]
= [3,200 m3/CD x 365 CD x 0.03] + 4,800 m3 + 7 CD x 3,200 m3/CD]

= 62,200 m3 at 15°C
Expansion factor for volume correction = 1.019 from 15°C to 40°C (Exxon Blue Book) or see Figure 4.
Required Working Storage = 62,200 m3 x 1.019 = 63,400 m3

• Determine volume of tankage required for turnaround protection:
Net Volume for Turnaround = Daily Production Rate x Turnaround Days
3,200 m3/CD x 8 CD = 25,600 m3 at 15°C
or = 26,100 m3 at 40°C
This requirement is much smaller than that for working storage. It is reasonable to assume that the pipestill turnaround can be
scheduled so that it does not occur during the peak heating oil season. Thus, only the working storage volume will be used.
Result:
Net Volume Required for Heating Oil Storage = 63,400 m3
(Heating oil is normally stored in cone-roof tanks. Refer to PROBLEM 1 to determine the actual tank gross volume and
dimensions.)

ENGINEERING Date
PROBLEM 3
Determine intermediate tankage volume for naphtha (POWERFORMING Unit feed).
Given:
PARAMETER CUSTOMARY UNITS EXAMPLE METRIC EXAMPLE

bbl m
3
• Naphtha (POWERFORMING Unit feed) 10,000 @ 60°F
SD 1,600 @ 15°C
production rate SD
bbl 3
• POWERFORMING Unit throughput 10,000 @ 60°F m
SD 1,600 @ 15°C
SD
• Pipestill turnaround time 2 weeks 2 weeks
• POWERFORMING Unit turnaround time 3 weeks 3 weeks
• Turnarounds do not occur simultaneously
• Maximum ambient temperature 100°F 40°C
Find: Determine the net storage volume required for POWERFORMING Unit feed.
Solution: (Customary units example)
• Determine net volume of tankage required for pipestill turnaround:
bbl
Net Volume = 14 Days x 10,000 = 140,000 bbl
Day
Expansion factor for volume correction from 60°F to 100°F = 1.025 (Exxon Blue Book, Page 8-31; use
Boiling Point = 300°F)
Required volume for pipestill turnaround = 140,000 bbl x 1.025 = 143,500 bbl
• Determine volume of tankage required for POWERFORMING Unit turnaround:
bbl
Net Volume = 21 Days x 10,000 = 210,000 bbl
Day
Required volume for POWERFORMING Unit turnaround = 210,000 x 1.025 = 215,300 bbl
Result:
Since the turnarounds do not occur simultaneously, use the larger of the two calculated volumes.
Net volume required for POWERFORMING Unit feed = 215,300 bbl (Naphtha is a low-flash stock and is stored in floating roof
tanks. Refer to PROBLEM 1 to determine the actual tank gross volume and dimensions.)

Date ENGINEERING

Solution: (Metric example)
• Determine volume of tankage required for pipestill turnaround:
Net Volume = 14 Days x 1,600 m3/SD = 22,400 m3
Expansion factor for volume correction from 15°C to 40°C = 1.025 (Exxon Blue Book)
Required volume for pipestill turnaround = 22,400 m3 x 1.025 = 22,960 m3

• Determine net volume of tankage required for POWERFORMING Unit turnaround:
Net Volume = 21 Days x 1,600 m3/SD = 33,600 m3
Required volume for POWERFORMING Unit turnaround = 33,600 m3 x 1.025 = 34,400 m3
Result:
Since the turnarounds do not occur simultaneously, use the larger of the two calculated volumes.
Net volume required for POWERFORMING Unit feed = 34,400 m3
(Naphtha is a low-flash stock and is stored in floating-roof tanks. Refer to PROBLEM 1 to determine the actual tank dimensions.)

ENGINEERING Date
FIGURE 1
GEODESIC DOME COVER
Center Dome Vent
Access Hatch
Panel Skin
Side Skirt
Peripheral
Vent Opening
Note 1
Pedestal
Column
Support
Tension
Ring Girder
Cut Away Section Shows:

Triangulated Space Frame
for Dome Cover.
Note 1: Peripheral Vent Openings shall be designed to prevent rain ingress.

DP22BF01

Date
Section
XXII-B
Single Deck Pontoon Floating Roof

Page
Continuous Automatic
December, 1999
Fabric Roof Supports Bleeder Vent

Rim
Hatch Pontoon Vent
36 of 49
DESIGN PRACTICES
Gauge Manhole
Roof Supports Deck

Deck Manhole
Screens
Pontoon Pontoon
Tank Check Level

Shell Valve Articulated Liquid
Pipe Drain Surface
Bottom Support for Legs
Double Deck Floating Roof

FIGURE 2
Continuous
Fabric
Gauge Rim
Hatch Manhole Automatic Bleeder Vent Emergency Drain Vent
Open Drain
TYPES OF FLOATING ROOFS
Circular Roof Support

Roof Support Manhole Manhole
Bulkhead Deck
ATMOSPHERIC STORAGE
Level
OFFSITES SYSTEMS STORAGE FACILITIES
Tank C
L Roof Liquid
Shell Surface

PROPRIETARY INFORMATION - For Authorized Company Use Only
Note: 1) Articulated Pipe Drain is Not Shown But is Equivalent to That Shown for Single Deck Pontoon Floating Roof DP22BF02
EXXON
ENGINEERING
ENGINEERING Date
FIGURE 3
FIXED ROOF TANK WITH INTERNAL FLOATING COVER
Vent Gauge
Manhole Hatch
Facia
Guide
Open Eave Wire
for Anti-Static
Ventilation Cable
Positive/Negative
Seal Pressure-Relieve
Hatchway
Peripheral
Rim Edge
Floation Tubes
Sleeve & Seal
Top Adjustable Legs Structural

(Two Set Points) Support Column
Inlet Nozzle
Internal Distributor
(Refer to Figure 9 for Further Details)
Distributor Can Be Elevated or Flush With the Tank Floor
DP22BF03

Date ENGINEERING
FIGURE 4
PETROLEUM TEMPERATURE GRAVITY RELATIONS
900 482
800 427
700 371
F
/60°
60°
.98
1.00
.96
.94
600 316
.92
.90
vity
.88
.86
Gra
.84
Temperature of Oil, °C
Temperature of Oil, °F
.82
cific
.80
.78
Spe
.76
500 .74 260

.72
.70
400 204
.68
.66
4
.6
2
.6
300 149
200 93
0
.6
8
.5
6
.5
4
.5
2
.5
0
.5
100 38
60 16
1.0 0.9 0.8 0.7 0.6 0.5 0.4
Spec. Gravity [Referred to Water at 60 °F (16°C)] DP22BF04

ENGINEERING Date
FIGURE 5
SEMI-AUTOMATIC WATER DRAWOFF SCHEME WITH AUTOMATIC TANK GAUGING
Oil Level
ATG Input/ LT
Encoder Unit % Oil.
Switch
Interface
Detector
Oil
Interface Man
Water Auto
Open
Close
Additional to ATG System

Note: Conventional automatic tank gauging shown but HTG is equally appropriate. DP22BF05
FIGURE 6
SEMI-AUTOMATIC WATER DRAWOFF SCHEME WITH NO AUTOMATIC TANK GAUGING
Oil Level
"Qty. % Oil
Present" Switch
Oil
Interface Man Open

Water Auto Close
Flowmeter
Stand-Alone System DP22BF06

Date ENGINEERING
FIGURE 7
FLEXIBLE HOSE DRAIN
Sump Inlet
External Floating Roof
Roof
Clamp And Clevis
Sump
Device Check
Valve
Ballasted Hose
DP22BF07

ENGINEERING Date
FIGURE 8
ARTICULATED PIPE DRAIN
C
L of Roof & Sump
Pontoon Roof In
High Position Sump Inlet
Swivel
Joints
Check
Valve
Swivel
Joint
Pontoon Roof In
Low Position
Sump Inlet
Swivel Joint
~
Slop
e
Tank DP22BF08
Bottom

Date ENGINEERING
FIGURE 9
INLET NOZZLE DIFFUSER
L Slots Weld Bind

On End
Tank Inlet 6" Typ
D D
Plan
DI
View
W
12" Typ
3/8" Guide Plates
@ 6'-0" (Min 2 Each Side)
Optional 12" Typ
Weld To Floor Only.
Flanged
Round Exposed Edges On
Connection
Tank Shell Floating Roof
With Internal Hose Drain.
Inlet Shell
1/2" Hole
in End of Pipe
Elevation
W
View
6" or More
(or as in Figure 3)
60 60 DIFFUSER DIMENSIONS
Dia. of
Flow Slot
Slotted Pipe Weld Length,
Rate Width,
Pipe, Schedule L (ft)
(gpm) (1)
W (in)
DI (in)
3/8" Tank 20-24 STD
20,000 8 16
Guide Bottom 12-14 STD
10,000 4 19
Plates O 16-18 STD
10,000 6 12
10,000 20-24 STD 8 8
6" or 5,000 12-14 STD 4 10
More 5,000 16-18 STD 6 6
5,000 20-24 STD 8 5
1/2" Dia
Drain Hole in End of Blind
Flange or Bottom of Pipe Formula for Determing
Length of Diffuser
1.28 Q +1
L=
V (48W + πW2 )
12"
W= Width of Slots (ins)
W L= Slotted Pipe Length (ft)
Q = Max Pumping in Rate, gpm
V = Max Permissible Velocity
Slot Detail Through Slots (ft/sec)(1)
Note:
(1) Max velocity through slots 3 ft/sec DP22BF09

ENGINEERING Date
FIGURE 10
LOW SUCTION NOZZLE AND SLOTTED SUCTION DETAILS
Low Suction Nozzle
8" 1'- 4"
5/8"
Max.
1'- 4"
2"
Tank Dia. > 80', Use 6"-Class150 RF Shell Nozzle
Tank Dia. ≤ 80', Use 4"-Class150 RF Nozzle
Slotted Suction
Seal End
Tank Shell A
F
E 6"
D
30° 30°
C
L
C
B
Section A-A
A A
1/2" Dia. Drain Hole
Pipe Size Dimensions in Inches

Inches A B* C D E F
4 3.7 6.0 8.3 1.5 8.5 76
6 4.6 7.9 11.2 2 14 76
8 5.2 9.5 13.8 2 26 90

10 6.1 11.5 16.9 2 39 90
12 7.1 13.5 19.9 2 56 90
16 8.8 16.8 24.8 3 61 96
*Dimension B Based on Use of API Low Nozzle Design
DP22BF10

Date ENGINEERING
FIGURE 11
DOUBLE BOTTOM LEAK DETECTION
Tank Shell
Rubber
Caulk 5
Crushed Stone New Bottom
Liner 4
Tell-Tale Pipes
3 4"
2 Liner
Existing Grade 1 Existing Bottom
Notes:
(1) Cathodic Protection
(2) GRP Lines Per IP 19-4-1
(3) Oiled Sand Corrosion Resistant Barrier or Dry Sand With Cathodic Protection
(4) GRP Lines Per IP 19-4-1
(5) Elastomeric Seal
Double bottom leak detection design. GRP liners are used for secondary
containment and corrosion prevention. For new designs, oiled
sand and/or cathodic protection can be used to mitigate soilside corrosion.
DP22BF11
FIGURE 12
IMPERMEABLE HDPE LINER LEAK DETECTION
Internal Tank Lining on

Top of Bottom Plate 2" Oiled Sand
Zinc Reference Electrode
4" Crushed Stone
General Fill
HDPE
Sheet Metallic or Leak Telltale Pipe (Slope
Plastic Sump down from center to outside)
This sketch shows a new tank with an impermeable HDPE sheet lining beneath it
for leak detection as discussed in IP 4-8-1. Corrosion of the soilside of the
tank bottom is mitigated by e.g. two inch oiled sand pad. This design has
been employed by several Exxon affiliates. DP22BF12

EXXON
ENGINEERING
Notes: 1) 2" of Oiled Sand. 8) 2" φ Min. Schedule 40 Austenitic Stainless Steel Pipe. Pipe Exits Outside
2) 4" Well Graded Crushed Stone or Crushed Gravel. of Ringwall 2 in. Above Grade w/6" Protrusion.
3) 1" Min. Thickness of Impermeable Sand-Asphalt Mix (Applied After Hydro Test) 9) Apex Drain Details:
4) Ringwall Constructed of Crushed Stone or Crushed Gravel. Leak Detection System Consisting of Cylindrical Section of 1"-2" Gravel
5) Flexible Membrane for Leak Detection System High Density Polyethylene or Crushed Stone Contained by a 12" φ Capped Section of Min. Schedule
Membrane - 40 mil. Thickness, With a Layer of Non-Woven Geotextile 40 Austenitic Stainless Steel Pipe. Membrane Attached Inside of
(Exxon GTF 225 D or Equivalent) Above and Below. Flexible Membrane Ends Pipe Using Internal Compression Ring or Internal Clamp of Stainless
Under Tank Shell. Steel. 2" φ Pipe (Note 8) Welded to 12" φ Pipe.
6) 40 mil. High Density Polyethylene Membrane Extend Throughout the Tank Pit. 10) Compacted Backfill.
Secondary Containment for Entire Diked Area. 11) Granular Fill.
7) The Crushed Stone or Gravel (Note 2) Extended Outward Past the Tank Wall 12) Zinc Reference Electrode.
Through Water Test. The Necessary Amount was Removed to Apply the
Sand-Asphalt Mix (Note 3) After Water Test.
Detail at ~
Dike Wall
TankWall
6" 3'-0" CL Tank
2 Ft
Limestone
10
12" 1'-6"
FIGURE 13
6 Secondary Containment
Membrane
Conc. Splash Tank Bottom
1 Tank Bottom
ATMOSPHERIC STORAGE
Block
2 1 5
Slope 1/48 2 12 Reference Electrode
OFFSITES SYSTEMS STORAGE FACILITIES
Wire to Test Station

Grade 3
7 12 5 Flexible Membrane
6"
2" Limestone 1.5 4 1.5 for Leak Detection

PROPRIETARY INFORMATION - For Authorized Company Use Only
Cover 11
9
11 8
18"
18"
10
Min.
Min.
Slope 1/12 6 8 6 Secondary

Date
Outwards

Subgrade Subgrade Containment for
SECONDARY CONTAINMENT AND TANK BOTTOM LEAK DETECTION
Section
Entire Diked Area

General Note: Check w/applicable IPs for latest details. Continues to About 2 Feet
XXII-B
DP22BF13
Above Limestone Cover on Diked Walls
Page
December, 1999
45 of 49
DESIGN PRACTICES
Date ENGINEERING
FIGURE 14
FLOATING ROOF SEALS
Tank Shell
Weather Shield
Primary Seal Fabric Fabric
(Seal Envelope)
Liquid
Vapor/Liquid
Interphase Pontoon
Seal Support
Assembly Bumper and Seal
Support Assembly
Metallic Seal
(a) Metallic Seal (b) Liquid-Mounted Seal

(Liquid-Filled)
Weather Shield
Weather Shield
Fabric
(Seal Envelope)
Gas
Fabric
(Seal Envelope) Foam
Vapor
Vapor/Liquid Space
Interphase Vapor
Vapor/Liquid Space
Interphase
Bumper
Bumper
(c) Vapor-Mounted Seal (d) Vapor-Mounted Seal

(Gas-Filled) (Foam-Filled)
DP22BF14

ENGINEERING Date
FIGURE 15
RIM-MOUNTED SECONDARY SEAL
Tank Shell Rim-Mounted Tank

Shell Rim-Mounted
Secondary Seal
Secondary Seal
Primary Seal Fabric
Fabric
Floating Roof
Floating
Roof
Liquid Filled Tube
(Bottom Immersed)
Counterweight
~
Seal Support
Assembly
Liquid
Metallic Seal
Mechanical Shoe Primary Seal Resilient Filled Primary Seal DP22BF15

Date ENGINEERING
➧ APPENDIX A
TANK MIXING GUIDELINES
BASIC OBJECTIVES
The basic reason for installing tank mixers is to prevent stratification and ensure uniform quality throughout the tank. This is
essential for tanks feeding process units or product blenders since non-homogeneous streams promote operating upsets and off
specification product blends. Mixers are also used to correct a tank which contains an off specification (offspec) product. In this
latter case, the corrective component(s) is added and the mixer is operated to achieve homogeneity. Mixers are also needed for
preventing sludge settling and suspending sludge in crude oil tanks. Long term settled sludge can cause a decline in storage
capacity and serious corrosion / fouling problems in the downstream refinery equipment.
Operational requirements typically set the maximum allowable time to achieve tank mixing objective(s). There is a tradeoff
between shorter mixing time and capital and operational costs (Larger pumps, lines and more fluid pumped and power
consumed), thus each case should be studied to get the optimal result.
There are two available methods for tank mixing, jet nozzles and side entry propeller (SEP) mixers. The choice is basically
economic although SEP mixers are generally used on crude tanks and on tanks storing high viscosity material. Jet mixers are
usually avoided on fixed roof tanks with light weight internal floating covers because of the potential for roof damage due to jet
stream impingement on the light weight roof.
See Section XIII A and B of the DP for the equations for sizing submerged jets and SEP mixers. These equations are applicable
to liquids with viscosities ≤ 300 cSt (300 x 10-6 m2/sec) and small differences in specific gravity (∆SG < 0.05). Consult ER&E
MIXING SPECIALIST for applications outside the viscosity and SG ranges.
TANK MIXING PARAMETERS
Mixing occurs by entraining the surrounding fluid into the jet stream produced by flowing a rundown stream through a nozzle (See
Figure A-1A) or operating a propeller. The produced jet should be large enough to achieve homogeneity within a reasonable
and predictable time. The basic parameter is the number of tank turnovers, i.e., the ratio of fluid circulated by entrainment to tank
working volume.
Mixing time is dependent upon whether or not the tank contents are in a stratified condition (SG differential > 0.1) and the
viscosity of the stored material. Refer to the tabulated information in Section XIII-B of the DP. The information shows the
number of tank turnovers required to achieve specific mixing objectives like homogeneity and destratification. Before
homogeneity can be achieved, a circulation pattern or destratification needs to be established. Thus, total mixing time is the sum
of the time required to destratify or setup circulation and the time required to achieve homogeneity.
Note that the information in Section XIII-B of the DP is predicated on having sufficient mixing power available for the entrained
stream to reach across the tank. With a grossly under-powered stream, homogeneity may never be achieved no matter how long
the mixing time.
GUIDELINES TO SOME MIXING PROBLEMS

• Adding light component to a tank with jet mixer. Assume, for example, a mogas product tank is offspec on RVP (RVP is
below specified maximum resulting in give-away) thus it is desirable to add extra light component(s), typically butane with a
SG difference of 0.10 to the tank. If the butane is added as a pure stream, there is a risk of it just bubbling through the tank
without being properly mixed. In addition, the flow rate of butane is likely to be low and would not create an effective jet.
Therefore, the butane should preferably be added to a recirculating stream as shown in Figure A-1B. The butane addition
rate should be such that SG difference of the recirculating stream to the tank bulk is less than 0.05.
• Adding heavy component to a tank with SEP mixers. Assume, for example, a fluxed dark product tank is offspec on
viscosity (viscosity is below maximum specified resulting in give-away), thus more dark product can be added. In this case,
the dark product can be added as a batch as long as the difference in SG is less than 0.05 and the SEP mixers operated
continuously to achieve homogeneity and minimize risk of stratification. If there is a larger difference in SG it is better to
recycle the tank's content through an in-line mixer while adding the heavy component.
• Crude oil blending in tanks. Assume a mix of different crudes is desirable to fill an APS unit. Crude blending should be
done from cleared tanks, (that is the tanks have been dewatered, sampled and inventory controlled) to a dedicated tank, not
by adding miscellaneous vessel imports on top of tank heels. The blending should preferably be done using an inline
blender, similar to regular product blending. The receiving crude tank's SEPs should be operated continuously during the
operation to minimize the risk of stratification and subsequent mixing time for homogeneity.
• Sludge suspension in crude oil tanks. It is recommended that mixers should be adequately designed and operated to
prevent sludge settling. Two technologies are available; SEP mixers and Rotating Submerged Jets (RSJs). Section XIII-B
provides design guidelines for SEP mixers. ERE mixing specialist should be consulted on the design of RSJs. In the event
excessive sludge has accumulated in a tank, sludge resuspension with mixers can cause serious operational and safety

ENGINEERING Date
problems in the refinery's downstream equipment. Various off-stream desludging methods can be applied, the selection of
which should be made through consultation with ERE specialists.
➧ FIGURE A-1
TYPICAL JET MIXER SYSTEM
A. RUNDOWN MIXING
Product
To Other Tank
Product Tanks
Jet Nozzle
Rundown Pump
Product
Tank
B. RECIRCULATION MIXING
Jet Nozzle
Export
Export/Recirculation
Pump
Additional
Component
Addition
DP22BFA1

Dp22b (Atmospheric Storage)

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OFFSITES SYSTEMS STORAGE FACILITIES DESIGN PRACTICES

ATMOSPHERIC STORAGE Section Page

PRINCIPAL TYPES OF ATMOSPHERIC STORAGE TANKS ....................................................................... 5

SELECTION OF THE TYPE OF ATMOSPHERIC TANK ............................................................................... 7

BASIC DESIGN CONSIDERATIONS ............................................................................................................. 8

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

ENVIRONMENTAL CONSIDERATIONS IN TANKAGE DESIGN ................................................................ 22

DESIGN SPECIFICATION CHECKLIST....................................................................................................... 27

SAMPLE PROBLEMS .................................................................................................................................. 28

APPENDIX A - TANK MIXING GUIDELINES ............................................................................................... 48

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

API BULLETINS AND STANDARDS

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

PRINCIPAL TYPES OF ATMOSPHERIC STORAGE TANKS

FIXED ROOF TANKS

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

PRINCIPAL TYPES OF ATMOSPHERIC STORAGE TANKS (Cont)

➧ GEODESIC DOME ROOFS

FLOATING ROOF TANKS

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

PRINCIPAL TYPES OF ATMOSPHERIC STORAGE TANKS (Cont)

SELECTION OF THE TYPE OF ATMOSPHERIC TANK

EXTERNAL FLOATING ROOF TANKS

INTERNAL FLOATING ROOF TANK

FIXED ROOF TANKS

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

BASIC DESIGN CONSIDERATIONS

DESIGN VALUES FOR INNAGE AND OUTAGE

TYPE OF TANK INNAGE, in. (mm) OUTAGE, in. (mm)(4)

ECONOMIC TANK SIZING

STRUCTURAL DESIGN CONSIDERATIONS

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

BASIC DESIGN CONSIDERATIONS (Cont)

LOCAL SITE CONDITIONS

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

BASIC DESIGN CONSIDERATIONS (Cont)

ENVIRONMENTAL IMPACT ON TANK BOTTOM DESIGN

SIZING CRUDE TANKAGE

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PROCEDURES (Cont)

SIZING PRODUCT TANKAGE

SIZING COMPONENT TANKAGE

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PROCEDURES (Cont)

Note: Typical volume units are Bbl or cubic meters.

SIZING INTERMEDIATE TANKAGE

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PROCEDURES (Cont)

GROSS TANKAGE VOLUME

FLOATING ROOF TANK FIXED ROOF TANK

Steam(1) All API Low All API Low

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PROCEDURES (Cont)

WATER DRAWOFF EQUIPMENT

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PROCEDURES (Cont)

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PROCEDURES (Cont)

TANK MIXING EQUIPMENT

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PROCEDURES (Cont)