Improving Industry Needs Construction of New Storage Tanks according to API 650

November 29&30, 2011 ISTANBUL - TURKEY

FERT GNGRM BUREAU VERITAS Oil & Gas, Energy Supervisor API 653 AUTHORIZED INSPECTOR

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CONTENT of PRESENTATION

1. Improving Industry Needs 2. Design - Basic design approach and verification 3. Fabrication - Important points for fabrication at workshops or site 4. Erection - Methods and their advantages/disadvantages 5. Testing - NDT, Pneumatic & Hydrostatic testing

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1. Improving Industry Needs

Global improvement on industry is going on with increasing population and technology. To solve raw material needs for serial production increasing number of storage tank is unavoidable. Increasing number of vehicle in traffic causes construction of new storage tanks. Old storage tanks, generally built up before 1970s need to be replaced with new ones due corrosion on material and wrong manufacturing/erection techniques in past. Natural reasons such as eartquake, wind, snow also cause new storage tanks or reinforcement on in-service tanks Change in service or operation cause new storage tanks or change in tank structure or geometry.
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API 650

CONTENT of PRESENTATION Othervise;

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1. Improving Industry Needs

Locally there are two refinery projects in Turkey, and one storage terminal for chemical or nutrition liquid storage. Countries especially in Middle East, Africa needs new storage tanks To standardize and share lessons learnt by other API was established in 1919. Issued first standart in 1924. For storage tanks beginning with API 12C, API 650 - Welded Tanks for Oil Storage code describes and defines rules for construction of new storage tanks. Recently 11th Ed. of API 650 is on the market. Mainly; materail, design, fabrication, erection, inspection of joints, welding requirements and marking were defined in API 650. Understanding of API 650 an follow its requirements can lead owners to avoid any failure/loss experienced by others.

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2. Design - Basic design approach and verification 2.1 Types of Atmospheric Storage Tank Roofs
The most common type of atmospheric storage tank is the fixed cone roof tank, These roofs are normally supported by internal structural but can be fully self-supporting in smaller diameters (typically, 60 ft [3 m] diameter or less). up to 300 ft (91.5 m) in diameter & 64 ft (19.5 m) in height (larger diameter tanks have been built, mostly outside the U.S.)

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2. Design - Basic design approach and verification 2.1 Types of Atmospheric Storage Tank Roofs
The floating-roof tank is designed to minimize filling and breathing losses by eliminating or minimizing the vapor space above the stored liquid. The shell and bottom of this type of tank are similar to those of the fixed roof tanks, but in this case, the roof is designed to float on the surface of the stored liquid. Older styles of floating roofs include single steel deck details without annular pontoons. Such roofs have no reserve buoyancy and are susceptible to sinking in service. Annular-pontoon and double-deck; roofs are external floating roof tanks. Some floating-roof tanks have fixed aluminium geodesic dome roofs installed on top of the tank shell to reduce product vapor loss or to eliminate the need to drain rainwater from the roof. These are considered internal floating roofs is a tank with a fixed steel cone roof over a floating roof.

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2. Design - Basic design approach and verification 2.1 Types of Atmospheric Storage Tank Roofs

Double-Deck

Annular Pontoon

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2. Design - Basic design approach and verification 2.1 Types of Atmospheric Storage Tank Roofs
Low-pressure storage tanks are those designed to operate with pressures in their gas or vapor spaces exceeding the 2.5 lbf/in.2 (18 kPa) gauge permissible in API Std 650, but not exceeding the 15 lbf/in.2 (103 kPa) gauge maximum limitation of API Std 620.

Plain Hemispheroids

Vapor Dome Roof

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2. Design - Basic design approach and verification 2.2 Materials used in construction
Section 4 of API 650 define materials can be used in construction of a storage tank. Accoding to this section mainly below materials can be used;
Also design metal temperature should be taken into account according to location of storage tank. Material type of shapes and pipe is also deifned in section 4. Welding electrode for; Material has Ut<550 MPa, E60,E70 series Material has Ut>550 MPa, E80 series

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2. Design - Basic design approach and verification

2.3 Basic Design Approach and Verification 2.3.1 Correct thickness?
Shell thickness easliy can be verified by 1-foot method;
td: design thickness tt: hydrotest thickness D:nominal tank diameter H:design liquid level G:specific gravity of product Sd:allowable stress for design St:allowable strss for hydrotest CA:corrosion allowance

In any case min thicknesses as follows;

Bottom plates shall be minimum 6 mm thick exclusive of CA unless othervise specified. API 650 offers 1800 mm width plates.
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2. Design - Basic design approach and verification

2.3 Basic Design Approach and Verification
Annular plate thickness shall be decided acc. to below table;

The ring of annular plates shall have a circular outside circumference, but may have a regular polygonal shape inside the tank shell, with the number of sides equal to the number of annular plates.

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2. Design - Basic design approach and verification

2.3 Basic Design Approach and Verification 2.3.2 With or Without Annular plate?
Bottom shell course in Group IV, IVA, V, or VI, butt-welded annular bottom plates shall be used unless maximum product stress for the first shell course is less than or equal to 160 MPa or the maximum hydrostatic test stress for the first shell course is less than or equal to 171 MPa. In this case lap-welded bottom plate maybe used.

2.4 Opennings in correct location?

Location shell or roof opennigs may be verified with below tables;

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2. Design - Basic design approach and verification

2.4 Opennings in correct location?

Tank design review can prevent many imperfection during fabrication or erection.
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3. Fabrication - Important points for fabrication at workshops or site

During fabrication of tank material in workshop or site maximum care shall be taken not to cause failure during erection or service. Edges of plates may be sheared, machined, chipped, or machine gas cut. Shearing shall be limited to plates less than or equal to 10 mm thick used for buttwelded joints and to plates less than or equal to 16 mm thick used for lap-welded Joints Shaping of shell plates before erection should be done according to below figure;

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3. Fabrication - Important points for fabrication at workshops or site Good engineering design can accelerate erection by pre-drilled openning. Drilling of telltale holes shall be done before erection Radius and weld bevel control during fabrication can prevent any time/effort loss during erection Proper marking of shell/bottom plates with a prestudied drawing can save time and effort during erection. Plates and tank material shall be loaded in a manner that ensures delivery without damage Shop primer on plates and protective oil on flange faces can prevent material from corrosion till final process

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4. Erection - Methods and their advantages/disadvantages 4.1 After foundation works and laying bottom/annular plates, there are mainly two different erection method for storage tanks; 1. Conventional method: Starting from bottom course and raising tank putting upper courses on top of bottom one via crane.

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4. Erection - Methods and their advantages/disadvantages 2. Jacking method: Starting from top course and raising bottom courses on bottom of top one via hydrojacking.

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4. Erection - Methods and their advantages/disadvantages 4.2 Advantages/Disadvantages of Each Method Conventional method needs crane which costs huge amount if erection works delay( generally occurs) Jacking method is safer especially against site accidents Conventional method provide less temporary welds and eventually less cleaning and NDT works. Jacking method provides generally working on ground level and high weld quality Conventional method is faster if no repair works retrospectively. Jacking method helps worker for inside work during raising of tank. Conventional method complicate final inspections Jacking method needs NDT results and repairs(if exist) before putting bottom one Conventional method complicate NDT works Jacking method needs more workmanship during raising operation. Convetional method is more dependent on climatic conditions
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4. Erection - Methods and their advantages/disadvantages 4.3 Important points during erection

Welding procedures and welder certificates shall be prepared according to ASME Sec.9. For welds on non-pressure parts AWS D1.1 can be used. The welding of the shell to the bottom shall be practically completed before the welding of bottom joints that may have been left open to compensate for shrinkage of any welds previously made is completed. Upper plate at a horizontal butt joint shall have a 4:1 taper when its thickness is more than 3 mm greater than the lower plate

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4. Erection - Methods and their advantages/disadvantages 4.3 Important points during erection Misalignment during shell welding, vertical or horizontal, shall be controlled. Limits around 1,5 and 3 mm, respectively. After first pass of shell-to-bottom weld from outside weld should be checked against leakage with suitable manner. Shell butt welds shall be examined with either RT or UT. Plumbness and roundness control shall be taken into account before hydrotest. Foundation requirements shall be provided to achive other dimensional tolerances.

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5. Testing NDT, Pneumatic and Hydrostatic Testing.

5.1 Pneumatic and Hydrostatic Testing Welds of bottom shall be checked with vacuum box with air pressure between 20kPa and 70 kPa. Before hydrotest pads shall be tested pneumatically with air up to 100 kPa During hydrotest water level shall be increased at least 50 mm above the weld of roof-to-shell(top angle) connection For carbon steel equipment where water contact exceeds 14 days, including filling and draining owner may consider adding an oxygen scavenger and a biocide, and raise the pH by the addition of caustic. Aim of hydrotest is checking welds against leaking as well settlement control. Roof plates shall be tested by vacuum box or bubble test. If bubble test is used, before draining water after hydrotest volume above water level shall pressurized with air not exceeding weight of roof plates.

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5. Testing NDT, Pneumatic and Hydrostatic Testing.

5.2 NDT(Non-Destructive Test) Number of RT film on shell welds shall be decide from below figure;

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5. Testing NDT, Pneumatic and Hydrostatic Testing.

5.2 NDT(Non-Destructive Test) We offer shortly; one spot from each first vertical, each T joint, one spot per 20 m vertical weld and one spot per 40 m horizontal weld . Annular plate butt weld shall be examined via RT RT shall be applied according to ASME Sec. 5 and evaluated according to ASME Sec 8. Penalty films shall be taken into account carefully. Magnetic and Liquid penetrant testing shall be applied according to ASME Sec 5. and evaluated according to ASME Sec.8. Moreover operator shall have eye vision capability test report not older than 1-year. Reinforcement of welds and undercut shall be xamined carefully according to limits given in Sec. 8 of API 650. Arc strikes are generally evaluated as harmless or ignored. However they can initiate big failure. Those shall be cleaned carefully.

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Bureau Veritas Turkey Services for Storage Tanks

API 650 DESIGN REVIEW PREPARATION WELDER QUALIFICATION & PQR REVIEW OF WELDING PROCEDURE SPECIFICATIONS 3.PARTY INSPECTION OF ERECTION & MANUFACTURING OCCUPATIONAL HEALTH & SAFETY DURING CONSTRUCTION API 653 - IN-SERVICE & OUT OF SERVICE INSPECTIONS AUTHORIZE INSPECTOR SERVICES NON-DESTRUCTIVE TESTS SETTLEMENT SURVEYS TANK BOTTOM SCAN BY MFL AND FLOOR SCANNER CERTIFICATION OF HYDROSTATIC TEST TRAINING ABOUT INSPECTION & CONSTRUCTION
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