Above ground storage tanks : practical guide to construction, inspection, and testing

390 Pages·2015·24.362 MB·English

by  Pullarcot, Sunil

Above Ground
StorAGe tAnkS
Practical Guide to Construction,
Inspection, and Testing
© 2015 by Taylor & Francis Group, LLC
K22265_Book.indb 1 4/20/15 5:46 PM

Above Ground
StorAGe tAnkS
Practical Guide to Construction,
Inspection, and Testing
Sunil Pullarcot

Boca Raton London New York
CRC Press is an imprint of the
Taylor & Francis Group, an informa business
© 2015 by Taylor & Francis Group, LLC
K22265_Book.indb 3 4/20/15 5:46 PM
CRC Press
Taylor & Francis Group
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Boca Raton, FL 33487-2742
© 2015 by Taylor & Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group, an Informa business
No claim to original U.S. Government works
Version Date: 20141028
International Standard Book Number-13: 978-1-4822-2203-6 (eBook - PDF)
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© 2015 by Taylor & Francis Group, LLC
Contents
Preface ...................................................................................................................xiii
1. Storage Tanks ..................................................................................................1
1.1 Introduction ...........................................................................................1
1.2 Classification of Storage Tanks ............................................................3
1.3 Classification of Above Ground Storage Tanks ................................5
1.4 Selection of Type ...................................................................................7
1.5 Two Common Types of Storage Tanks ...............................................8
1.6 Design and Construction Standards for Above Ground
Storage Tanks .........................................................................................9
1.7 API Specification for Storage Tanks ...................................................9
1.8 Jurisdiction of Various Standards for Storages ...............................11
1.8.1 API 650: Welded Steel Tanks for Oil Storage ...........................11
1.8.2 API 620: Design and Construction of Large, Welded,
Low-Pressure Storage Tanks .....................................................12
1.8.3 ASME Section VIII Div (1): Rules for Construction of
Pressure Vessels ........................................................................12
1.9 Layout of API 650 Based on April 2013 Edition ..............................13
2. Classification of Storage ..............................................................................15
2.1 Some Basics about Flammable and Combustible Liquids ............15
2.2 Classification of Storage (NFPA 30) ..................................................15
2.3 Classification of Storage (Institute of Petroleum) ...........................16
3. Tank Farm Layout .........................................................................................19
3.1 Considerations .....................................................................................19
3.2 Typical Tank Farms .............................................................................21
3.3 Spacing of Tanks in Tank Farms .......................................................22
3.4 Spacing of Tanks per NFPA 30 ..........................................................22

3.5 Spacing of a Tank for Petroleum Stocks as per the Institute
of Petroleum Guidelines ....................................................................28
3.5.1 Storage Classes I, II(2), III(2) ..................................................28
3.5.2 Storage Classes II(1) and III(1) ..............................................28
3.6 API Tank Sizes for Layout Purpose (Based on API 650) ...............31
3.7 Summary of Refinery Storage Tanks ...............................................32
3.8 Use of Floating and Fixed Roof Tanks .............................................32
3.8.1 Floating Roof Tanks ...............................................................32
3.8.2 Fixed Roof Tanks ....................................................................33
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vi Contents
3.8.3 Considerations to Decide between Floating Roof
Type and Fixed Roof Type ....................................................33
3.8.4 Tank Type Selection Guidelines ..........................................35
3.9 Storage Tank Capacity Chart .............................................................36
4. Tank Design ...................................................................................................37
4.1 Tank Design Considerations .............................................................37
4.2 Design Aids Available ........................................................................38
4.3 Basis for Designing .............................................................................40
4.4 Design Calculations ............................................................................40
4.5 Drawings ..............................................................................................41
4.6 Approved for Construction Drawings and Documents ...............42
4.7 Documents for Statutory and Client Approvals .............................43
4.8 Design Change Note ...........................................................................43
4.9 As-Built Documents ...........................................................................44
5. Tank Foundation ...........................................................................................45
5.1 Considerations for the Selection of Foundation .............................45
5.2 Types of Foundations .........................................................................46
5.2.1 Compact Soil Foundations ....................................................46
5.2.2 Crushed-Stone Ring Wall Foundations ..............................46
5.2.3 Concrete Ring Wall Foundations ........................................47
5.2.4 Slab Foundations ....................................................................47
5.2.5 Pile-Supported Foundations ................................................47
5.3 Handing Over the Foundation ..........................................................47
6. Sequence of Mechanical Works for Storage Tank Erection .................49
6.1 Preliminary Works on Award of Contract ......................................49
6.2 Responsibility Matrix (Head Office and Site) .................................49
6.3 Organization Setup at the Site ..........................................................51
6.3.1 Introduction ............................................................................51
6.3.2 Organization Chart ...............................................................52
6.4 Design, Drawings, and Documents Approval ................................52
6.5 List of Documents ...............................................................................54

6.6 Preparation of Bill of Materials with Specifications.......................57
6.7 Inquiry and Purchase of Raw Materials ..........................................57
6.8 Materials Procured from Stockists or Traders ................................58
6.9 Purchase or Transfer of Construction Equipment to the Site .......59
6.10 List of Equipment Required at the Site ............................................59
6.11 Work Contracts ....................................................................................60
6.11.1 Subcontract for Nondestructive Testing (NDT) ................60
6.11.2 Subcontract for Scaffolding ..................................................60
6.11.3 Subcontract for Surface Preparation, Internal Lining,
and External Painting ...........................................................60
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Contents vii
6.11.4 Calibration and Certification of Storage Tanks .................60
6.12 Local Contracts and Purchases at the Site .......................................61
7. Tank Erection ................................................................................................63
7.1 Storage Tank Erection .........................................................................63
7.2 Inspection of Raw Materials ..............................................................63
7.2.1 Plates and Pipes......................................................................68
7.2.2 Pipe Fittings and Flanges .....................................................68
7.2.3 Fasteners and Gaskets ...........................................................69
7.2.4 Consumable Such as Electrodes ..........................................69
7.3 Identification and Traceability of Raw Materials ...........................69
7.4 Marking of Plates ................................................................................70
7.4.1 Marking of Annular, Sketch, Bottom, and
Roof Plates .....................................................................71
7.4.2 Marking of Shell Plates .........................................................71
7.5 Cutting of Plates and Other Pressure and Load
Retaining Parts ................................................................................72
7.6 Inspection of Plates after Cutting and Edge Preparation .............73
7.7 Bending of Plates .................................................................................73
7.7.1 Direction of Bending .............................................................73
7.7.2 Prepinging ..............................................................................74
7.7.3 Templates ................................................................................76
7.8 Laying of Bottom (Annular, Bottom, and Sketch) Plates ..............80
7.8.1 Annular Plates ........................................................................80
7.8.2 Bottom Plates ..........................................................................81
7.8.3 Sketch Plates ...........................................................................81
7.8.4 Annular and Bottom Plate Layout ......................................81
7.8.5 Surface Preparation and Coating of Bottom Plates ...........82
7.8.6 Laying of Annular Plates ......................................................82
7.8.7 Recommended Weld Joint Configurations ........................85
7.8.8 Laying of Bottom and Sketch Plates....................................86
7.8.9 Welding Sequence of Annular, Sketch, and Bottom
Plates ........................................................................................88
7.8.10 Annular Plate Welds..............................................................88

7.8.11 Bottom Plate Welds ................................................................89
7.8.12 Weld between Annular and Bottom Plates ........................89
7.8.13 Testing of Welds .....................................................................90
8. Erection of Shell Courses, Roofs, and Other Appurtenances .............93
8.1 General..................................................................................................93
8.2 Conventional Method .........................................................................93
8.3 Bygging or Jacking Up Method ........................................................95
8.4 Comparison of Erection Methodology ............................................96
8.5 Erection of Shells by Conventional Method ....................................98
8.5.1 Shell Cutting Plan (Shell Development) .............................98
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viii Contents
8.5.2 Erection of Shell Courses ......................................................98
8.5.3 Erection of Roof Structure and Roof Plates......................105
8.5.4 Fit Up and Welding of Closure Plate.................................107
8.5.5 Fit Up and Welding of First Shell Course to Annular
Plate ........................................................................................108
8.6 Methodology for Tank Erection by the Jacking Up Method ......108
8.6.1 Brief Overview .....................................................................108
8.6.2 Detailed Working Procedure .............................................109
8.6.3 Salient Features and Limitations of the Jacking Up
Method ..................................................................................111
8.6.4 Arrangements for Jacking Up ............................................112
8.6.5 Pictures of the Jacking Up Method ...................................113
8.7 Erection of Roof Structure and Cone Roof Plates.........................114
8.8 Shell Appurtenances.........................................................................114
8.9 Manufacture of Subassemblies .......................................................114
8.10 Installation of Appurtenances.........................................................115
8.11 Spiral Stairway, Handrails, Platforms, and Other Support
Attachments .......................................................................................120
9. Welding .........................................................................................................123
9.1 Weld Edge Preparation .....................................................................123
9.2 Typical Weld Joints ...........................................................................123
9.3 Restrictions on Types of Weld Joints ..............................................124
9.3.1 Shell Vertical Joints ..............................................................126
9.4 Welding Processes ............................................................................127
9.5 Welding Procedure Specifications ..................................................128
9.6 Procedure Qualification ...................................................................128
9.7 Welder Qualification .........................................................................129
9.8 Welder’s Identification Cards ..........................................................130
9.9 Welding Sequence .............................................................................130
9.9.1 Cleanliness of Weld Groove and Adjacent Area .............130
9.9.2 Metal Temperature and Preheat ........................................131
9.9.3 Reasons for Preheating before Welding ...........................132
9.9.4 Interpass Temperature ........................................................132

9.9.5 Back Gouging, Grinding, and NDT ..................................133
9.10 Electrode Storage and Its Drying ....................................................133
9.10.1 Storing Low Hydrogen Stick Electrodes ..........................134
9.10.2 Redrying: Low Hydrogen Stick Electrodes .....................134
9.10.3 Redrying Conditions: Low Hydrogen
Stick Electrodes ................................................................135
9.10.4 Storing and Redrying: Non-Low
Hydrogen Electrodes ........................................................135
9.10.5 Redrying Conditions: Non-Low Hydrogen Stick
Electrodes ..............................................................................136
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Contents ix
9.11 Weld Repairs ......................................................................................136
9.12 Weld Repair Procedure ....................................................................137
10. Inspection and Testing of Welds .............................................................139
10.1 Summary of Inspection and Tests ..................................................139
10.2 Butt Welds ..........................................................................................142
10.3 Fillet Welds (Pressure Retaining) ...................................................143
10.4 Other Structural Welds on Shell and Roof (Inside and
Outside) .............................................................................................143
10.5 Inspection (Dimensional) ................................................................144
10.5.1 Annular and Bottom plates ................................................144
10.5.2 Shell ........................................................................................146
11. Nondestructive Testing .............................................................................151
11.1 Radiographic Testing ........................................................................151
11.2 Minimum Number and Location of Radiographs Required
as per API 650 ....................................................................................151
11.3 Weld Maps with Pictorial Presentation of Radiography .............154
11.3.1 Table 11.1 for Pictorial Presentation of Radiography
(Shell Thickness 22 mm to 8 mm)......................................154
11.3.2 Table 11.2 for Pictorial Presentation of Radiography
(Shell Thickness 28 mm to 8 mm) ......................................158
11.4 Other Requirements for Radiography ...........................................162
11.4.1 Technique ..............................................................................162
11.4.2 Personnel ...............................................................................162
11.4.3 Procedure ..............................................................................162
11.4.4 Radiographs ..........................................................................162
11.4.5 Acceptability Norms ...........................................................162
11.4.6 Progressive or Penalty Radiography .................................162
11.4.7 Repair of Defective Welds ..................................................163
11.4.8 Records ..................................................................................163
11.4.9 Specific Requirements for Radiography from Some
Clients in the Oil and Gas Industry ..................................163
11.5 Ultrasonic Testing .............................................................................165

11.6 Magnetic Particle Testing .................................................................165
11.7 Liquid Penetrant Testing ..................................................................166
11.8 Visual Examination or Testing ........................................................166
11.8.1 Visual Examination Strategy..............................................166
11.8.2 Vision Requirement for Visual Inspectors .......................167
11.8.3 Acceptance Criteria for Visual Examination ...................167
11.9 Weld Maps..........................................................................................168
11.10 Documentation of NDT ....................................................................168
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x Contents
12. Other Tests ...................................................................................................169
12.1 Vacuum Box Testing .........................................................................169
12.1.1 Vacuum Box Test Procedure ...............................................170
12.1.2 Vacuum Box Testing (Standard and Client
Requirements) ......................................................................170
12.1.3 Equipment .............................................................................171
12.1.4 Types of Vacuum Boxes ......................................................172
12.1.5 Methodology of Testing ......................................................176
12.1.6 Acceptance Criteria .............................................................177
12.1.7 Records ..................................................................................177
12.2 Pneumatic Testing of Reinforcement Pads ....................................178
12.2.1 Requirements........................................................................178
12.2.2 Test Pressure and Methodology ........................................178
12.2.3 Arrangements .......................................................................178
12.3 Hydrostatic Testing of Tank ............................................................181
12.3.1 Testing of Tank Shell ...........................................................181
12.3.2 Standard and Client Requirements for Hydrostatic
Testing ...................................................................................181
12.3.3 Recommended Contents for the Hydrostatic Test
Procedure ..............................................................................182
12.3.4 Water Filling and Draining Rates ......................................183
12.3.5 Filling of Test Medium ........................................................183
12.3.6 Visual Inspection .................................................................184
12.3.7 Safety Precautions ...............................................................184
12.3.8 Repair and Retest .................................................................184
12.3.9 Draining ................................................................................185
12.3.10 Cleaning ................................................................................185
12.3.11 Documentation .....................................................................185
12.4 Measurement of Settlement of Tank during Hydrostatic
Testing .................................................................................................186
12.5 Alternate Tests in Lieu of Hydrostatic Testing .............................187
12.6 Testing of Roof ...................................................................................188
12.7 Testing of Roof for Appendix F Tanks ...........................................188

13. Cleaning, Internal Lining, and External Painting ..............................191
13.1 Cleaning after Hydrostatic Test ......................................................191
13.2 Planning for Surface Preparation and Lining or Painting ..........191
13.3 Surface Preparation (Write-up Courtesy M/s Transocean
Coating, Rotterdam) .........................................................................195
13.3.1 High-Pressure Freshwater Cleaning .................................196
13.3.2 Solvent Cleaning ..................................................................196
13.3.3 Hand Tool Cleaning ............................................................197
13.3.4 Pickling ..................................................................................197
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