ERECTING Oil

STORAGE STEEL
TANKS

Eng. R. Hijjawi

Prepared By
Eng. Rizeq A. Hijjawi
Engineerstalk –Webinar # 44
June-19-2021
Tanks

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 Open Tanks
• This type no roof
• shall not be used for petroleum products.
• Atmospheric tank.

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Fixed Roof Tanks
• Atmospheric tank (free vent)
• Low pressure tanks (approx. 2 Kpa g of internal pressure)
• High pressure tanks (approx. 5.6 Kpa g of internal pressure)

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API Standard 650-Welded Tanks for Oil Storage
• Establishes minimum requirements for material, design, fabrication, erection, and
testing for vertical, cylindrical, aboveground, closed-and open-top, welded carbon
or stainless-steel storage tanks in various sizes and capacities for internal pressures
approximating atmospheric pressure (internal pressures not exceeding the weight
of the roof plates)
• Applies only to tanks whose entire bottom is uniformly supported.
• Tanks in non-refrigerated service that have a maximum design temperature of 93°C
(200°F) or less. Eng. R. Hijjawi
• The Standard has requirements given in two alternate systems of units :
–SI units, or
–US Customary units.
API Standard 650 (American Petroleum Institute)pdf. file
https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=&cad=rja&uact=8&ved=2ahUKEwjN5KLiiZ_xAhVIasAKHQeWC_IQFjAAegQI
BRAD&url=https%3A%2F%2Flaw.resource.org%2Fpub%2Fus%2Fcfr%2Fibr%2F002%2Fapi.650.2007.pdf&usg=AOvVaw05jamd4Fz3oABmoNJVl6s2
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API 620, Design and Construction of
Large, Welded, Low-Pressure Storage
Tanks, API that gives requirements for
the design and construction of large,
welded storage tanks with pressures
in their gas or vapor spaces of not
more than 15 lbf/in.2 gauge.
API 620 regulates the design and
manufacture of large steel low-
pressure storage tanks, usually larger
than 300 feet (90m) in diameter. By
contrast, API Standard 650 is typically Eng. R. Hijjawi
used for carbon, stainless steel and
aluminum tanks located in terminals,
refineries, pipelines and other process
facilities.
API 620 (pdf. File)
https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=
&cad=rja&uact=8&ved=2ahUKEwin8YLL4KPxAhVIz4UKHa-
VA90QFjABegQIBBAF&url=https%3A%2F%2Flaw.resource.org%2Fpub%
2Fus%2Fcfr%2Fibr%2F002%2Fapi.620.2002.pdf&usg=AOvVaw09qeNm_
ruQSriVZ7aRZXF8
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Shell Design
• Shell Design
• –Shell designed on the basis that the tank is filled to level H with a specific
gravity (SG) product value furnished by the customer.
• Required shell t (include CA= Corrosion Allowance) for both product and
hydrotest
• Nominal thickness used Eng. R. Hijjawi
• Material specification
• Allowable stresses
API 650-Shell Design (pdf. File)
https://www.api.org/-/media/Files/Certification/Monogram-APIQR/0_API-Monogram-APIQR/Advisories-Updates/Addenda-
Errata/API_650_12th-Edition_Errata-1_July-2013.pdf?la=en&hash=5B43907105A771A2181FC3E17E8C8B9DAEDE1771
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Variable Design
Point Method
• The variable point method is an
alternative to the 1-foot
method and can be used for
tanks in excess of 200ft in
diameter. ... API 650 storage
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tanks are often designed to
work at temperatures of up to
500ºF (260ºC). For these higher
temperature designs, the
allowable stress of the material
decreases.

https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=&cad=rja&uact=8&ved=2ahUKEwj4uPOpoJ_xAhVux4UKHdY2AlkQFjABegQIEhAD&url=h
ttps%3A%2F%2Fcoade.typepad.com%2Ffiles%2Fptq-q4-2016-designing-storage-tanks.pdf&usg=AOvVaw0MIs_ej_QsQzZG1y--4pB3
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http://www.ijirset.com/upload/2017/may/144_Design.pdf
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Fixed Roof Design

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Plate Load Test

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Steel Storage Tank Erection
Two types of storage tank erection methodology have become widely accepted and popular. The first one is the Conventional Method
of Tank Erection & the other is the Tank Jacking method. Both of these tank erection methods are accepted by the API 650 and
constructor. The selection of tank erection method basically depends on the site location or workshop where we are making these
tanks.
There is a popular myth that API 650 guides us to adopt the tank erection methodology. But that is not true. API 650 only guides us in
the design, fabrication, welding, hydro testing & inspection of storage tanks.
A. Conventional Method of Tank Erection
In the conventional methods, cranes are used for tank erection as a sheet by sheet method. At first, the bottom and annular plates
are erected. Then the lower course shell is erected and finally, the upper course shell is erected. Refer to Fig. 1 which shows an
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example of a double-deck floating roof Tank erection by the conventional method. Suppose there are a total of 9 shells in a Tank so
the tank erection sequence shall be 1st shell coarse, 2nd shell coarse, 3rd, and then in last 9th shell coarse
Advantages
a. Suitable for all diameters and height
b. Dimensional Control -Shell and bottom shape close to designed ones
Disadvantages
a. long duration of Erection/Construction
b. Working at Heights (Safety Concern )
In the case of small diameter Tank, the tank is fabricated at the workshop and then brought it to site by a trailer for erection. But the
handling should be proper to avoid buckling, bending, and any damage.
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B. Conventional Method of Tank Erection
Tank Erection by Jacking Method
In order to achieve proper verticality of the tank, it is very important that the foundation is perfectly leveled. Foundation shall be
inspected by the tank fabricator to ensure compliance with tolerances specified in the foundation Drawing.
Relative levels in the peripheral area (where the tank shell is to rest) at a minimum of 16 points may be marked. Relative levels of all the
points may be checked by keeping one point as the reference point.
Differences in levels should not exceed limits given in the code / construction Drawings.
2. MARKETING REFERENCE POINTS
Before starting the mechanical erection, the following reference points are to be marked.
Elevation with reference to plant elevation has to be marked on the 16 points mentioned above on the vertical face of the tank
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foundation slab to check the settlement of the foundation during the hydrostatic test of the tank.
The “X” and “Y” axis of the tank should also be marked on the vertical face of the foundation, i.e. 0/360o, 90o, 180o and 270o. These co-
ordinates will later be the reference points for marking of the tank nozzles, etc. after transferring the same co-ordinates to the tank shell.
3. ERECTION AND WELDING OF TANK BOTTOM
a. Annular Plates
• If drain nozzle is attached to annular plate, RF pad for the same shall be welded to annular bottom plates and tested in accordance
with Drawing and WPS before erection of bottom.
• Place and adjust the annular plates according to the co-ordinates and orientation given in the Drawing.
• The steel backing strips shall be placed below all the radial welding seams of the annular plates.
• Weld the joint according to the welding details in the Drawing and the WPS.
• The crown of the seam must be ground flush at the shell location. This is to ensure proper bearing between bottom and shell course.
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ERECTION PROCEDURE FOR FIELD ERECTED TANK USING JACKING METHOD
a. b. Bottom Plates
• The bottom shall be assembled on top of foundation according to the Drawing.
• Cut the sketch plates according to the dimensions on the Drawing and the cutting layout for rectangular plates.
• Whenever a plate is crossing a lap joint, the plate must be joggled down to a shape in way that there is sound contact between the
plates as per details given in the Drawing.
• Weld the transverse according to the welding Details given in the Drawing and the WPS.
• Welding may be done with one or two welders on the same joint. Preferably alternate seams should be welded. Leave sufficient
time in between welding two layers to avoid overheating.
• After welding the alternate long seams, weld the balance long seams in the same manner as mentioned above.

4. ERECTION AND WELDING OF TANK TOP SHELL COURSE

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All bottom joints are to be tested by the vacuum box method or as specified.

ERECTION OF TANK SHELL COURSE USING HYDRAULIC JACKING SYSTEM IS CARRID OUT IN REVERSE ORDER (i.e. TOP MOST SHELL COURSE ERE.
CTED FIRST AND THEN JACKED UP IN SERIES IN ORDER TO HAVE LOWER SHELL COURSE FIT UP AT LAST) .
• Mark the location of the shell Periphery location on the annular plates.
• Erect Spacers (Elevators) of Heavy I-Section of 400-450 mm depth at approx. 2Mtr space along the periphery and tack weld to the
tank bottom.
Erect TOP shell course on Elevators along the periphery on the Elevators locating the vertical weld joints as per orientation given in
the Drawing. Provide adequate support on shell to maintain verticality.

Adjust the plates and fit up the vertical joints by using erection tools.
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• After proper alignment, carry out tack welding of vertical joints. Check the dimensions according to drawings.
• Weld the vertical joint according to the approved weld procedure.
• Minimum clear height required for jacking is 3.5 m. In case if shell plate width is 2Mtr, in that case
• install two shell course plates before installing jack. (i.e. 2nd to TOP first on Elevators and then TOP Shell course) .
• Install the second shell course as prescribed for the first course.

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• After welding of the vertical joints of the first and second shell course, carry out the fit up and the welding of the horizontal joints
between these two shell courses.
• Carefully check the verticality and roundness of each shell course and ensure that tolerances are maintained as per API 650 standard.
• All horizontal welds shall be performed by two or more welders 180o apart and welding in the same direction.
5. ERECTION AND WELDING OF TOP CURB ANGLE
• Mark the location of the weld joints of the Top Curb on top shell course according to the Orientation given in the Drawing.
• Erect the curb angle segments & align them.
• Weld the curb angle. Take precaution to avoid distortion during the welding.

6. ERECTION AND WLEDING OF ROOF

• Cut the roof plates according to Drawing.
• If rafters are shown in the drawings, bend the rafters to required radius as per Drawing.
• Place the roof plate petals on a temporary jig and install and weld the rafter as shown in Drawing.
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Install and weld the gusset plates & end plates to the rafters as per Drawing.
• Fabricate and weld the center ring as per Drawing. Install and fillet weld the inner top plate of the center ring. The outer top plate of the
center ring shall only be welded after erection of the entire roof.
• Erect a temporary column in the center of the tank.
• Place the center ring on top plate of the column at a distance indicated in the Drawing.
• Erect and weld the roof plates along with rafter.
• The outer edge of the roof plates should be welded with the curb angle as per Detail given in the Drawing.
• Install outer top plate of center ring.
• Weld rafters with outer top ring of center ring in slot & at outer periphery.
• Erect and weld the crown plate over the center once all the major work inside the tank is completed.
• Please ensure to keep Roof Man way and Vent Nozzle open during entire execution of the tank to ensure proper venting in the tank.
• All attachment on roof (Such as Handrail, Steps, Nozzles etc.) may also be fixed and welded in this stage as indicated in picture below.
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7. INSTALLATION OF HYDRAULIC JACKS
• Marking for Base Plate of Jacks shall be done on Bottom Plate.
• Number of Jacks shall be determined by the Rule of Thumb to keep radial distance of 3.14Mtrs. between two jacks in case of tanks having Diameter
less than 30Mtr. Dia. In case if Tank Dia is more than 30Mtrs. jacking quantity shall be confirmed with Design Engineer.
• Location of the jacks as marked in bottom plate shall be transferred on ID of the erected tank shell course.
• Weld Lifting Lug and Fend-Off Lug on Erected Tank Shell Course with Stitch welding as indicated in image below. Ensure Lifting Lug Welding quality by
virtue of suitable NDT Method (i.e. DP or MPT) .

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• Install lifting Trestles on located as marked on Bottom plate of Tank. Please ensure parallelism of Lifting Lug, Fend-Off Lug with Lifting Trestle.
• Install Jacks on the Trestle
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• Please refer to Jacks Assembly Drawings as attached herewith at Annexure – A as Reference guide for assembly and installation of
jacking system and for the purpose to identify major parts as mentioned in section above.

• Interconnect all Jacks with Hydraulic Power Pack System (Pos. No. 3 of Annexure-B). Sketch of the Hydraulic Hose Circuit is as
shown in attached Annexure – B. Please refer Manufacturer Manual to ensure proper Hydraulic hose circuit assembly.
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8. ERECTION OF SHELL COURSE USING HYDRAULIC JACKS
• Ensure that Shell course as erected on Elevators (As detailed in Section 4.0) is welded in all Respect and Plumpness of the same is
maintained and all required NDT is completed for the said Shell Course.
• Lift the Shell Course by Hydraulic Jacks maintaining normal lifting speed of the Hydraulic Jacks (Normal Speed shall be 100mm per Minute).
• Check visual plumpness and roundness of the shell course after every interval of 500mm. Lifting operation can be aborted at any point in
time by putting operating lever to Neutral position for power pack. Upon reaching to maximum required height Lock the operating lever.
• Please ensure to lift the Shell course at least 50mm more than the required clear shell height of the next shell course. Required Height shall
be calculated from the top of Elevators. This is to ensure that Second Shell course Plates can be moved in place and Fit up Margin is
available for Circular Seam Fit up.
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• Erect Inserted shell course on Elevators along the periphery locating the vertical weld joints as per orientation given in the Drawing. Provide
adequate support on shell to maintain verticality.
• Adjust the plates and fit up the vertical joints by using erection tools.
• After proper alignment, carry out tack welding of vertical joints. Check the dimensions according to drawings.
• Weld the vertical joint according to the approved weld procedure.
• After welding of the vertical joints, carry out the fit up and the welding of the horizontal joints between these two shell courses. The lifted
part of the tank is lowered down slightly in order to settle properly on the newly erected shell course, in order to achieve proper alignment
of horizontal joint.
• Carefully check the verticality and roundness of each shell course and ensure that tolerances are maintained as per API 650 standard.
• All horizontal welds shall be performed by two or more welders 180o apart and welding in the same direction.
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Make a level reading from shell course #1 up to course #3 to monitor the plumpness of the tank which is 1/200 of the total, tank height as
per API 650 Standard.
• Upon completion of the welding release the jacks and lower the same one at a time using a rope.
• Carry out welding of lifting and fend-off lugs on Shell Course which is resting on Elevators.
• The external wind girder shall be erected and welded only after the welding of the horizontal joint located just below the wind girder is
completed.
• Radial butt weld of wind girder shall be done as per Drawing.
• Ensure to complete Fit up and welding of Wind girder, spiral staircase & shell appurtenances including nozzles of respective shell courses
immediately after erection of the shell course but before lifting of that particular shell course. Ensure to complete all requisite NDT Testing
and cleaning of shell as simultaneous operation before lifting of shell course to avoid operations at elevated heigh.
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• Structural simulation
erected storage tank
with jacking system
Example Design
http://fajaryannu.blogspot.com/2016/08/structural-
simulation-erected-storage_14.html

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• Take lift of the completed Shell course adopting the procedure
as explained above.
• Cycle of operations as above shall be repeated until the Bottom
Shell Course is erected successfully.
• Before the assembly/inserting of the last shell course, remove
all the Elevators/spacers. Erect plates of the bottom shell
course on the tank annular plate.
• Upon proper alignment of vertical shell joints release the jacks
and lower it slightly to ensure settlement on Annular/Bottom
Plate.
• Don not fix Smallest segment of Bottom Shell Course in order
to facilitate removal of jacking equipments. Upon releasing of
jacks and settlement of bottom shell course of Bottom plate
remove jacking equipments and complete fit up of last
segment. Eng. R. Hijjawi
• Check final elevations and straightness of the tank and carry
out horizontal welding between both Shell Course and
subsequently between bottom shell course and annular plate.
PRECAUTIONARY NOTES
Lifting Operations should not be taken up in strong winds or when
the wind velocity exceeds or is expected to exceed the “maximum
safe wind speed for lifting” which in ideal condition is more
than22.5 Meters/Second. If tank is in lifted position, and strong
winds (more than 22.5 meters/second) are expected, the tank
shall be tied using guy ropes to reduce the impact of load on jacks
due to wind load.
ENSURE THAT WELDING OF TRESTLE BASE PLATE AND TRESTLE SHALL NOT
BE REMOVED IN ANY CASE TILL COMPLETE ERECTION OF TANK IS
COMPLETE.
Video : https://youtu.be/dJlNS-2CjrY
9. INSTALLATION OF SHELL AND ROOF NOZZLES
• Install and weld all the nozzles as indicated on the Drawings for each shell course before taking lift of the shell course to avoid any Fit-up and
welding activity at heights.
• Pads shall be pneumatically leak tested according to API 650 Standard.

10. STAIRWAY, PLATFORM, HAND RAILING & CLIPS

• Install the stairway and platform as shown in the Drawing for each shell course simultaneously with the jacking cycle.
• Install the roof hand railing as Drawing simultaneously in order to avoid any Scaffolding and work at heights.
• Weld pipe support clips as per Drawing.
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11. REMOVAL OF SCAFFOLDING
• Remove all cleats, blank nuts and other temporary attachments by grinding. The surface must be grounded smooth.
12. NON-DESTRUCTIVE TESTING (NDT)
NDT shall be carried out as specified in the inspection & test plan and API 650 standard. Ensure to complete
NDT for respective shell while it is been lifted by Hydraulic Jacking. In a way it was ensure to complete within
the scaffold reach of 3Mtrs.
1. Visual Testing (VT).
2. Non-Destructive Kit Test(Liquid penetrant Inspection / LPI).
3. Vacuum Box Bubble Testing
4. Hydrostatic pressure
5. Magnetic Flux Leakage
6. Saturated Low Frequency Eddy Current Eng. R. Hijjawi
7. Ultrasonic Thickness Testing
8. Mass Spectrometer Leak Testing
9. Alternating Current Field Measurement.
10. Radiography
11. Ultrasonic Testing in Lieu of Radiographic Testing.
NDT of Welded Steel Tanks pdf. File
https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=&cad=rja&uact=8&ved=2ahUKEwj6y8LByorxAhUvyYUKHc4PDrg
QFjAAegQIAhAD&url=https%3A%2F%2Fndtlibrary.asnt.org%2Fscholar%2Faccess%2F2011%2FNDTofWeldedSteelTanks.pdf&usg=AOvVa
w1rNx76cqkYqxzFH8P2jyxq
Visual Testing (VT).

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Non-Destructive Kit Test(Liquid penetrant Inspection / LPI).

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https://youtu.be/QpU5JyhNVgQ
Vacuum Box Testing
1. SCOPE
The objective of the vacuum box technique of bubble leak testing is to locate leaks in a pressure boundary that cannot be directly pressurized. This is
accomplished by applying a solution to a local area of the pressure boundary surface and creating a differential pressure across that local area of the
boundary causing the formation of bubbles as leakage gas passes through the solution.
2. PURPOSE
The purpose of this procedure is providing a guideline to carry out the Vacuum box test to check soundness of annular joints, bottom( long seam & short
seam)and welding joints for annular plates.
3. REFERENCE CODE

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1. API-650 (Latest edition) 7.3.4 & 8.6 Eleventh edition2. ASME Sec-V.
4. EQUIPMENT
4.1. The Vacuum box test is performed by using a box with visible window of fiber glass (i.e.6” Wide by 30” long metallic box with a fiber glass). The open
bottom is sealed against the tank surface by a sponge rubber gasket. The test scheme shall have suitable connections, necessary valve and calibrated
Vacuum gauge.
4.2 According API 650 Sec. 8.6.3 A partial vacuum of 21 kPa (3 lbf/in.2, 6 in. Hg) to 35 kPa (5 lbf/in.2, 10 in Hg) gauge shall be used for the test.
If specified by the Purchaser, a second partial vacuum test of 56 kPa (8 lbf/in.2, 16 in. Hg) to 70 kPa (10 lbf/in.2, 20 in. Hg) shall be performed for the
detection of very small leaks.
4.3 The Test scheme shall be demonstrated with sample test block by application bubble solution at site before conduction the test on the job. The
bubble forming solution shall produce a film that does not break away from the area to be tested, and the bubbles formed shall not break rapidly due to
air drying or low surface tension, soaps or detergents designed specifically for cleaning shall not be used for the bubble forming solution.
Video
https://youtu.be/JMz0kjPPjVA
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Hydrostatic pressure
Hydrostatic Testing Requirements according to API Standard 650, Welded Tanks for Oil Storage.
https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=&cad=rja&uact=8&ved=2ahUKEwjN5KLiiZ_xAhVIasAKHQeWC_IQFjAAegQI
BRAD&url=https%3A%2F%2Flaw.resource.org%2Fpub%2Fus%2Fcfr%2Fibr%2F002%2Fapi.650.2007.pdf&usg=AOvVaw05jamd4Fz3oABmoNJVl6s2
Water Filing
1) The foundation settlement readings are to be checked at regular intervals.
2) Water shall be filled up to top of shell.
3) The foundation settlements will be determined by the site management, the level instrument shall be set up at least 1 1/2 times tank diameter away
from the tank when tank elevation readings are taken.

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The measurements of the settlement shall be performed as follows:
✓ 1st reading prior to filing.
✓ 2nd n reading approx. 24 hours after attaining 1/4 of the filling level (+ 600mm/2ft).
✓ 3rd reading approx. 24 hours after attaining 1/2 of the filling level.
✓ 5th reading approx. 24 hours after attaining 3/4 of the filling level .
✓ 6th reading approx. 24 hours after attaining the specified filling level.
✓ 7th reading after emptying.
In case of non-uniform settlements of the foundation of > 15mm (referred to 10m circumference) or uniform settlements of < 10mm in 24 hours or a uniform settlement over 50 mm
(2 in.) , the filling operation shall be interrupted. The filling operation shall not be resumed until examination by an expert for soil mechanics has been performed with due
consideration to special instruction while the procedure is being monitored continually. In the case of critical soil conditions, an expert for soil mechanics shall continually supervise
the measurements of settlement.

4) Check shell visually.

5) Tighten the nut on the anchor bolt.
13. RELEASE THE TANK FOR BLASTING & PAINTING
Painting shall be carried out as per approved procedure and standard specification. Each coat shall be inspected and recorded by Painting
Inspector. Final inspection will be carried out with Client or 3rd Party Inspector. Holiday test should be performed inside the tank

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Roof Air Raising Operation
On The LNG Tank
lift a 600-tonne and 80 meters in diameter steel
dome from the ground level 42 meters high, The
roof of the LNG storage tank holding 160 thousand
m3 was raised on the airbag, consisting in a
controlled change in air pressure generated under
the roof dome. The whole operation lasted exactly
188 minutes. The roof was lifted with a speed of
approximately 20 cm / min. Six blowers were used
for lifting operations, of which two were spare. It
might seem that raising such a huge construction
requires high-performance blowers. Nothing could
be more erroneous! Blowers with similar

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parameters are used in inflatable roofs over tennis
courts in winter season. The speed of roof raising
operation was controlled in two ways. The first
involved regulation of blowers’ valves. The second
method consisted in regulating the flow of air
under the roof with air pressure relief valve. The
horizontal position of the roof during raising
operation was maintained by means of the leveling
system composed of 26 steel ropes, each of 16 mm
in diameter. Prior to lifting, the roof had been
balanced with a special ballast mitigating the load
differences of the equipment suspended
underneath the roof.
When the roof reached its designed position 42
meters above the ground, it was fixed to the
compression ring by means of mounting brackets
with wedges and further it was welded to the ring.
The blowers were stopped as soon as 90% of the
circumferential roof welding had been completed.
Video : https://youtu.be/_UfZYOlcF1k