Storage

tank construction pdf

File Size 46.88 MB Authors Wayne B.

Geyer Number of Pages 360 Publisher Taylor & Francis ISBN 9780824785895 Samples A survey of manufacturing and installation methods, standards, and specifications of factory-made steel storage tanks and appurtenances for petroleum, chemicals, hydrocarbons, and other flammable or combustible liquids. It chronicles the trends towards
aboveground storage tanks, secondary containment, and corrosion-resistant underground steel storage systems. Shop-fabricated tanks: introduction - a history of storage tank systems; historical perspective on standards and codes; history of the uniform fire code; quality control on USTs and ASTs; UST and AST fabrication; storage tank specification
considerations; to bury or not to bury - steel tank technology decisions. Underground storage tanks: UST design - the wall thickness question; development of UL standards for underground steel tank safety; development of ULC standards for underground storage and handling of flammable and combustible liquids; federal UST regulatory programme;
steel UST technologies; underground storage tank installation; UST performance; corrosion and cathodic protection on underground storage tanks; how to specify UST system equipment. Aboveground storage tanks: AST design; development of UL standards for aboveground steel tank safety; development of ULC standards for aboveground storage
and handling of flammable and combustible liquids; secondary containment for noninsulated steel aboveground storage tank systems; AST environmental regulations; plan review and inspection of aboveground storage tanks; aboveground storage tank installation; how to specify AST system equipment. Storage tanks - Standards - United States,
Storage tanks - Design and construction, Industrial chemistry, Technology: general issues, Sanitary & municipal engineering Quality control of the welding joints in the course of tank construction should imply: The use of welding methods, ways and scope of control of the welding joints, applicable to the tank’s importance level; The use of effective
technological welding procedures and materials according to the stipulations of metal frameworks plan and Work Execution Plan; Carrying out technical and construction design supervision. The table contains information on methods of quality control of the welding joints, applicable depending on the controlled element of the tank: Control zone
Control method visual and measuring vacuum radio ultrasonic capillary (color) overpressure BOTTOM Bottom joints + + - - - - Bottom joints at a distance of 250 mm from the outer edge + + + - - - SHELL Vertical joints of the 1st and 2nd zones + - + +¹ - - Vertical joinsof remaining zones + - +² + - - Horizontal joints + - +² + - - Crosshairs of vertical
and horizontal joints + - + - - - Branch pipe-to-shell joints + + - + - - Joint between a collar of a branch pipe (hatch) and 1m a belt of a shell + - - - + + Joint between a collar of a branch pipe (hatch) and a wall (except for the 1st belt) + - - - - + Radial joints of stiffening rings + - - - - + Spots of removal of assembly devices, welded joints of structural
elements after their heat treatment + - - - + - Bottom-to-shell joint + + - - + - ROOF Radial joints of the support ring + - - + - - Joints of roofing, roofing shields + + - - - + Branch pipe-to-roof joints + + - - - - FLOATING ROOF Joints of boxes (compartments) and plugs of racks + - - - - + Joints of the central part + + - - - - Branch pipes-to-roof joints + + -
- - - 1 allowed the use of ultrasonic testing2 allowed the use of radiography3 control breakdown «chalk-kerosene» hold up welding joint from the inner side The scope of physical control of welding joints (in percentage to the joint’s length) of the tank shell, depending on the tank’s class of hazard, should correspond to the requirements of the table:
VOLUMES of the PHYSICAL CONTROL of WELDED JOINTS of TANK SHELL, as % of the length of the seam Control zone hazard class IV III II I 1 000 – 10000m³ 10000 –20000m³ vertical welded connections: in zones 1-2 20% 25% 50% 100% 100% in zones 3-4 5% 10% 25% 50% 100% in zones 5-6 2% 5% 10% 25% 50% the zones above the 6-
th - - 5% 10% 25% horizontal welds: in zones 1-2 3% 5% 10% 15% 20% in zones 3-4 1% 2% 5% 5% 10% in zones 5-6 - - 2% 2% 5% in other zones - - - 2% 2% While choosing the areas of control the prevailing attention should be paid to the areas of joints’ crossing. Assembly butt-joints of the tanks installed with coiled method with the loading capacity
from 1000 m³ and more must be controlled on the full length of the joints. The results of tests and quality control of the welding joints are fixed in certificates and acts and represent the essential supplements to the documents for the tank. 7.2. Final tests after the oil storage tank construction The final stage of the tank testing is the hydraulic
pressure test, meant to check the tightness of connections and the durability of construction on the whole. Tanks with fixed roof without a pontoon are additionally subject to extra pressure and relative under pressure from the inside. The table below stipulates the tests that need to be done for tanks of different types (1 - tanks with fixed roof without
a pontoon, 2 - tanks with fixed roof and a pontoon, 3 - tanks with floating roofs). № type of test 1 2 3 1 Watertight test + + + 2 Strength test of tank body under hydrostatic load + + + 3 Air pressure tightness test of a fixed roof + - - 4 Test the stability of the tank body by creating a relatively rarefaction inside the tank + - - 5 Buoyancy test of floating
roof - + + 6 Rolling ladder performance test - - + 7 Testing the stability of the base of the tank with the determination of absolute and uneven draft along the contour of the bottom, roll of the tank profile of the central part of the bottom + + + Hydraulic pressure test of the tanks with floating roofs or a pontoon are done before installing the rim seals.

The tests of a tank of any type are carried out based on the testing program, included in the metal framework design project and Work Execution Plan. The testing program should include: Stages of testing, stipulating the level of loading/discharge of water and curing time; Rates of excessive pressure and relative under pressure, test curing time;
Scheme of visual inspection; Demands for measuring the necessary geometrical parameters of the construction elements of the tank and its foundation; Testing results’ processing, checking calculations (if necessary), final report on usability and operating regime of the tank. 7.2.1. Hydraulic pressure tests of a tank In the course of hydraulic pressure
test the tank is gradually filled with water to the planned level. The loading is performed in stages with certain time gaps, meant for supervising its settlement and the state of welding joints, and for carrying out other measuring and inspection, stipulated by the testing program. If leaking from under the edge of the bottom or in the first ring of the
shell is revealed in the course of testing, the water is fully discharged (removed). If cracks are revealed in the shell seams the water is discharged to the level lower than the discovered defect. If the defect appears in the 2nd-6th ring, the water is removed to the level one ring lower the defect. If the defect appears in the 7th ring and higher – the
water is removed to the 5th ring. After the defects are eliminated the testing goes on. Tanks for storing liquid materials with the mass density, exceeding that of water, as well as the tanks, installed at sites without water availability, can be tested with the product itself. Prior to such tests all welding joints of the shell, bottom, roof and manway
plates/fitting pipes, and also connections of shell with the roof and the bottom should be tested for leak tightness.

The tank filled to the planned level must be kept under load within the following period: Vertical steel tank V≤10000 m³ — 24 hours; Vertical steel tank V=10000-20000 m³ — 48 hours; Vertical steel tank V≥20000 m³ — 72 hours. The tank is considered to pass the test if no leaking appears on its surface of at the edges of the bottom within the test
period, if the level of test product does not decrease, if the settlement (sinking) of the foundation and basement becomes stable. The hydraulic pressure test is recommended to be carried out at the temperature level not less than +5 °С. If the test is done in winter period the water should be heated, or its permanent circulation should be provided so
as to prevent its freezing in the pipes and gate valves, and to prevent frosting of the tank shell. 7.2.2. Pressure/under pressure testing for the tank’s body and roof: Fixed roof of a tank without a pontoon is tested for excessive pressure with the tank filled to the level, which is 10 % lower the planned level, with keeping the load for 30-minutes.
The pressure is provided by the flow of water with all roof manway plates tightly closed. In the course of testing the full visual inspection of welding joints of the fixed roof is done. The steadiness of the tank body is checked by relative under pressure inside the tank, filled with water to the level of 1.5 m, keeping the tank under the load within 30 min.
The relative under pressure is provided by the discharge of the liquid product with all manway plates tightly closed. If no signs of unsteadiness are revealed (no canning, no buckles), the shells and roofs are considered to pass the test for relative under pressure.
The excessive pressure is applied at the rate of 25 % higher the planned level, the relative under pressure – 50 % higher the planned level, if the design documents do not contain other demands. After the acceptance test is done, it is not allowed to weld any construction elements to the tank. It is possible to perform corrosion preventive procedures,
heat insulation and installation of equipment, stipulated in the design documents. After the hydraulic pressure testing is done, the actual technical condition of the tank’s metal framework, basement and foundation should be evaluated. 7.2.3. The basic demands for the arranging and performing the tests: The final testing of a tank for durability,
steadiness and leak tightness is done after all welding and assembly procedures are over, the quality of all construction elements, including welding seams, is checked and accepted by the technical supervision organization. All tests are done according to the technological chart, included in Work Execution Plan. Technological chart should include:
The order and regime of the hydraulic pressure test; The order and regime of testing for excessive pressure and vacuum; Arrangement of temporary pipelines for water loading and discharging with safety and shutoff valves’ installation; Control panel; Labor safety requirements in the course of testing. Temporary pipeline for water loading and
discharging should be arranged outside the area of embanking. The scheme of water discharge is worked out for each particular case. In the course of testing the water is often pumped from one tank to another, and from the last one to the firefighting tank of temporary water body. Diameter of the pipeline for loading and discharging water should
correspond to the estimated level of loading-discharge operations’ efficiency. Apart from the operation scheme of flow and discharge of water, an emergency unloading scheme should be foreseen in case cracks appear on the tank’s body.

For emergency purposes it is recommended to use one of the intake-dispensing fitting pipelines and technological pipeline with a valve outside the area of embanking. It is essential to set and specially mark with preventing and safety signs the borders of danger zone for the testing period. If an embanking or a protective shell is arranged round the
tank, they are considered to be the border of the danger zone. In case the tank is installed without embanking, the limits of the danger zone are determined by the radius, drawn from the center of the tank for the distance equal to two diameters of the tank. The testing is done by the assembly organization accompanied by representatives of technical
supervision service and construction design supervisor. After the tests are finished, the installation specialists and the ordering customer sign a certificate (an act), stating the finish of the metal frameworks’ installation and acceptance of the tank for further corrosion preventive procedures, installing equipment and other works.

The Method Statement for storage tank construction provides detailed information on the procedure and rules for conducting all fabrication, erection, and testing of the storage tanks and similar static equipment. All the tasks / Activities should be completed with utmost care with good workmanship and in accordance with the specifications to realize
satisfactory completion of the entire activities. This document will provide a reference for a proper methodology to realize the activities during a proper sequence for fabrication, Erection, and Testing of the storage tanks.API 650IS 803ASME Sec IXApproved Drawing / SpecificationASME Sec VFig. 1: Storage Tanks in a Tank FarmThe storage tank
construction methodology can be performed in the sequence listed below:Identification of Tank MaterialsTank Construction and FabricationAnnular and Bottom Plate FabricationShell Plate FabricationRoof Plate FabricationAppurtenancesSpiral Stairway and handrailingStorage Tank ErectionAnnular Plate layingBottom Plate layingErection of Cone
Roof plates and StructuresShell Course ErectionAppurtenances installationAll items required for tank fabrication like Plates, fittings, and other components of the tankage system must be clearly identified by marking heat numbers by hard-punching on each part. Each weld joint shall be marked with a joint Number with Welder Number.All
fabrication works like tank material identification, marking, cutting, rolling and welding must be performed as mentioned in the latest API 650. The workmanship shall be good in every respect. It must be meeting all safety, Quality Control & Non-Destructive Testing requirements, with the coordination of the Engineer-In-Charge.Lay all the plates,
Structural & pipes in such a fashion that facilitates proper checking of dimensions & heat no.Mark the components as per the drawings.Mark the plates as per the drawingPerform the cutting operation after proper inspection.All the cutting operations shall be administered by Gas Cutting.Grind the cut edges smoothly to get rid of burrs and slag.Stack
the plates at designated places within the fabrication yard in proper Sequence.The backing strip shall be fitted and tacked with an annular plate as per the drawing.After completion of the fabrication underside of the annular and bottom plates shall be blast cleaned and painted as per the specification to the satisfaction of the Engineer-in-
charge.Check the Joint Position, Root gap for welding after welding Inspection by weld visual & NDT as per API 650.Fig. 2: Tank Shell and Bottom Plate FabricationLay all the plates within the open area such as how easy it is for marking and cutting.Mark the plates as per the drawing and to the satisfaction of the Engineer-in-charge.The cutting
operation including beveling shall be administered by the gas-cutting method on all four sides.Grind the cut edges smoothly to get rid of slag and burr.The stings-prepared plates shall be shifted by crane to the rolling area.The plates shall be fed to the rolling machine.

by means of a crane & proper lifting tools and tackles.The plate shall be rolled as per drawing details and therefore the radius shall be checked using a Template.Proper care shall be taken for the graceful curvature. 36’’ Long (5 to 6 mm thick). The template shall be wont to check rolling curvature accurately.The Template shall be checked and
cleared by the inspection authority.The rolled plates shall be inspected and shall be within 3 mm of the tolerance limit.The rolled plates shall be shifted to the shot blasting yard to hold out the shot blast as per specification.Final profile and dimensions check shall be administered before sending for erection.Mark the roof plate as per the drawing.All
the cutting operations as per requirement shall be administered after getting clearance from the inspection authority.All the cutting operations shall be administered by the gas-cutting method on all four sides. Grind the cut edges smoothly to get rid of burrs & slag.Structural items of the roof shall be fabricated as per the drawing.These roof plates
shall be shifted to the blasting yard to hold out the blasting and paintingMark the specified items of the Appurtenances as per the drawing. All the cutting operations as per requirement shall be administered after getting clearance from the inspection authority.All the cutting operations shall be administered by the gas-cutting method.Grind the cut
edges smoothly to get rid of burrs & slag.The Flange face is covered with an appropriate cover to guard against damage during handling, fabrication, and transportation.The whole shell nozzle, roof appurtenance, i.e. flanges, flanges to pipe joint, and other requirements, etc. Shall be fabricated as per approved drawings.All the fabrication and welding
activities shall be administered after the stage-wise inspection wherever required.The NDT requirements are as per code specification.All the structural items shall be straightened before marking and cutting.Mark the components as per the drawing.All the cutting operations, as per requirement shall be administered after getting the clearance from
the inspection authority.All the cutting operations shall be administered by the gas-cutting method.Grind the cut edges smoothly to get rid of burrs & slag.Fabrication like fitting, welding, drilling, etc. shall be administered as per drawing and after the clearance from the inspection authority.After fabrication of these structural items shall be blasted
and painted as per requirement.Fig. 3: Handrailing of Storage TanksThere are two methods for storage tank erection:the Jacking method &the conventional method.The conventional method is tough & unsafe as compared to the jacking method that’s why the jacking method for Tank erection is used everywhere.In the jacking method, we calculate
the overall weight of tank ages except for the bottom & deck, and accordingly, jacks are used.
The number of jacks to be used is directly subjected to the weight of the tank to be lifted.Fig. 4: Jacking method of tank erectionCheck the extent of the foundation as per specification Latest API 650 clause 8.4.2. After getting clearance for annular plate laying, mark the 0 degrees, 90 degrees, 180 degrees, and 270 degrees coordinates on the
inspiration from the point of reference.Lay the annular plate as per the approved drawing. Out radius of the annular plate shall be on the positive side (5 to 10 mm.) so as to realize the ultimately required radius after weld shrinkage.The orientation of the annular plate joint shall be as per the approved drawing.Fit from the annular plate’s joints shall
be administered using proper jigs and fixtures as shown in the drawing.Care shall be taken while fit-up, such that there shouldn’t any gap between the annular plate and backing strip.Annular plate joints welding shall be administered by welding alternative joints at four quadrants.Qualified welders shall be engaged for the welding work consistent
with WPS. If any defect is found the defect weld shall be removed by grinding and re-weld and Conducting the LPT check test.Repeat the sequence until the defect is cleared.Complete the welding, and clean the ultimate weld surface by wire brushing and grinding.Remove the jigs and fixtures which were used for the fit-up of the annular joint and
grind the tack.Radiography shall be taken as per API-650 Sec-8.Lay the middle plate on the inspiration top as per the drawing.With the coordination of the Centre, plates lay rock bottom plates consecutively as per the drawing.Laps shall be maintained while the fit-up of a short seam and long seam as per drawing.Temporary tack weld is to be
performed on the Long-seam to avoid uneven movements, while the fit-up and welding of the short seam are.Short seam welding is going to be administered alternatively to avoid distortion.After the completion of short-seam welding, remove the temporary tacks on the Long- seam by grinding to facilitate the long-seam fit-up.
Short seam welding is going to be administered alternatively to avoid distortion.After the completion of short-seam welding, remove the temporary tacks on the Long- seam by grinding to facilitate the long-seam fit-up.Minimum laps shall be maintained while the fit-up of the long seam is as per the approved drawing.Joggling shall be administered by
hammering wherever necessary. (Three plates Joining junction.)Before starting the welding, channels shall be tacked along the long seam to avoid distortion. After completion of shot seam welding long seam welding is going to be administered alternatively to avoid distortion. a professional welder shall be engaged and welding shall be performed as
per the approved WPS.After Completion of welding thoroughly cleans the weld joint by wire brushing and grinding.Sketch to annular plate joint shall be welded only after shell-to-bottom joint welding.All rock bottom plate joints vacuum box tests shall be administered as per the approved Process and code specifications.If any defect is found the defect
weld shall be removed by grinding and re-weld and conducting the vacuum box test. Repeat the sequence until the defect is cleared.After completion of the highest two shell courses erection, fit-up, welding, and curb ring fit & welding shall be done.Erect the fabricated Centre Drum, Roof Truss, and cross girders as per drawing.Complete the welding
of the Roof structure by approved welders and as per approved WPS. Erect and Lay the Roof plates on the structure as per the Drawing. While fit from the short seams and long seams Lap to be maintained as per the Drawing.Weld the short seams by welding the alternative joint or sequence mentioned within the drawing to stop the distortion.Provide
proper support lengthwise of the long seam and weld the joints as per the drawing sequence.Roof Nozzles and top shell nozzles fit-up and welding shall be carried out as per the approved drawing and subsequently, it’s to be correlated with the priority piping drawing.Fig. 5: Spiral Stairway of Storage TanksAfter the completion of the welding of the
Annular plates and bottom plates, mark the tank’s inner radius on the annular plates.Fix 25 Nos.
of erection tools at equal intervals on the annular Plates & transfer the within tank diameter on the stools.The last 2 shell courses shall be erected by the conventional method.Balance shell courses shall be erected by the Jacking method.The rolled shell plates shall be shifted to the tank foundation area stacked around the periphery by using a
crane.Proper care shall be taken while handling the rolled plates.Care shall be taken that the shell plate is erected to the diameter marked on the annular plate. Jigs and fixtures shall be used to align the shell plates.Complete the fit-up except for the ultimate joint which shall be fitted and welded after completion of the welding of the opposite joints.
(To avoid shrinkage).Peaking shall be checked at the top, middle, and bottom of the vertical joints employing a Sweep board of 36” long. Plumpness shall be checked for the verticality of the shell course at every 60° and shall be within the tolerance (tolerance 1/200 of the entire shell height).For perfect verticality, channels shall be provided at the
regular interval inside the shell course (3 to five meters) providing the channels shall facilitate the alignment shell course.Tack welds of the fitted vertical joints shall be ground smooth. Offer for inspection and obtain clearance from Engineer-in-charge for the vertical fit-up Complete the primary side welding by using qualified welders.Care shall be
taken while welding to avoid peaking and therefore the roundness distortion.After completion of first side welding, the back-chip shall be administered for sound metal from the other side of the weld by grinding.Back-chipped grooves shall be offered for inspection before starting the welding.Complete the 2nd side welding using qualified
welders.Joint Nos. & welder No. shall be marked on both sides of the weld joint. Care shall be taken to avoid peaking and roundness distortion. Clean weld joints from each side by wire brushing and grinding. After completion of welding from each side remove all the temporary jigs and fixtures and flush grind the tacks. (Do the weld refill wherever
required) and therefore the portion checked by M.P.T.Check the plumpness, circumference and therefore the radius, offer for inspection to the satisfaction of the Engineer-in-Charge.
While erecting subsequent coarse 3mm thick spacers shall be kept between the shell courses.Erection channels shall be fixed between the jacked shell and to be erected shell course plates at regular intervals to align and hold the last shell in a vertical position.Check to peak at vertical joints of shell employing a sweep board of 36″wide, acceptable
tolerance shall the as per API-650.Complete welding of last course vertical seam inside after getting clearance from the Engineer-in-charge. Back chip & welding shall be administered following as same as for other shell courses to the satisfaction of Engineer – in – Charge.After completion of welding, weld visual, verticality & circumference shall
be verified and recorded to the satisfaction of Engineer-in-Charge. Fit up the Horizontal seam between 2nd shell courses & 1st shell courses.Check Verticality of the last shell course, Verticality (plumpness) tolerance shall be as per API – 650 (max. out of plumpness at the highest of the shell relative to the rock bottom of the shell to not exceed 1/200
of total shell height from top of the last shell to Bottom).While welding care shall be taken for banding and therefore the roundness. Back-chip shall be administered by grinding for the sound metal and to the satisfaction of Engineer-in-Charge. Complete the 2nd side welding and clean the joint thoroughly from each side by grinding and wire brushing.
Check banding, plumpness, and record within the approved format to the satisfaction of Engineer – In-Charge.Offer welds visual to the satisfaction of Engineer-In-Charge. Mark the RT spots as per the instruction of the Engineer -In Charge, and complete the RT as per API – 650 requirements. Offer the RT film for reviewing to the Engineer-In-Charge
and if any repair occurs the repair spot shall be repaired by grinding for the sound metal, Re- weld the repair spot as per code API -650 sec-8 requirements.Take the repair spot RT and re-offer for the inspection to the satisfaction of Engineer-In- Charge. Spiral staircase Erection shall be administered as per drawing including brackets & avoiding
fouling with welds.Remove all the temporary cleats and tacks by grinding. If any defect is found the defect shall be repaired by grinding the defect area for the sound metal plus 150mm from both ends of the defect.Conduct the DP test on the repair spot. perform the entireProcess until the repair is cleared to the satisfaction of Engineer – In –
Charge.After completion of the shell to the bottom outside welding visual inspection is going to be administered to the satisfaction of the Engineer-In Charge.On completion of the shell to bottom welding / NDT and having completed all erection and welding work on the tank inside associated with the roof and roof structure, all unwanted materials,
and scrap shall be far away from inside the tank.RT of the vertical and horizontal joints shall be completed.Sketch to Annular plate joint fit up shall be administered after completing the shell to bottom welds.Vacuum box test shall be administered for rock bottom plate short seam, long seam, and sketch to annular plate joint. If any repair occurs an
equivalent shall be repaired and re-tested as per the approved procedure and API-650.Fig. 6: Storage Tank Construction at SiteFlanges to pipe joint shall be prefabricated and required NDT shall be completed before erection.Mark the nozzle location as per the drawings. Cut the openings by gas cutting after proper Inspection-by-inspection
authority.Erect the nozzles as per the orientation & the elevation shown within the drawing. Install RF. pads wherever required before nozzle erection.Suitable jigs & fixtures shall be provided to stop the distortion during the welding.Orientation, elevation & projection shall be maintained as per drawing and offer for the inspection clearance. Proper
care shall be taken for welding by providing jigs & Fixtures to stop distortion.Welding shall be as per WPS and to be welded by the qualified welder.The man-Hole neck shall be fabricated and therefore the longitudinal joint shall be radiographed. All the RF Pad weld shall be pneumatically tested at a pressure of 1.05 Kg/Cm².
The pneumatic test shall be administered to the satisfaction of the engineer in charge.All the shell nozzles finally weld from each side and RF Pads welds shall be inspected visually and by LPT, to the satisfaction of the engineer-in-charge.link to How to Clean Pipelines?link to What is NFPA 37? NFPA 37 vs NFPA 110 (PDF)