Vertical Cylindrical Storage Tank Calibration

Technologies and Application

Srini Sivaraman
SK Japan
March 2012
API Conference & Expo Singapore 2012

Calibration Overview - 1
Process by which the volume in a tank in relation to the liquid height (up
to maximum fill height) is established
The diameter of the courses is determined by field measurements using
following technologies

Reference Standards:
API Chapter 2.2 A:

Manual

API Chapter 2.2 B:

Optical Reference Line Method (ORLM)

API Chapter 2.2 C:

Optical Triangulation Method (OTM)

API Chapter 2.2 D:

Electro Optical Distance Ranging Method (EODR)

API Standard 2555:

Liquid Calibration
2

Calibration Overview - 2
All new tanks must undergo calibration
Have access to internal for accurate deadwood determination
Datum plate (reference plate at the bottom) flatness and level check and
correction as necessary
Calibration after successful hydrostatic test

All tanks in service must undergo recalibration or re computation

Recalibration at set frequency or after repair

Either set by customs or local regulations
General informative guidelines per API Chapter 2.2 A
Re computation only under certain conditions

Frequently Asked Questions

Do you have to empty the tanks for re calibration
NO

Can you calibrate the tank at any liquid level

Yes

Can you calibrate the tank when the tank is moving (receiving or
discharging)
No, you cannot calibrate the tank while the tank is in motion. The tank level
must be steady and no movement in and out of the tanks

Does product temperature impact volume

Yes. It results in expansion of tank shell wall and the additional volume can be
significant

Can calibration be undertaken over the insulation

No, not for custody transfers and inventory
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Frequently Asked Questions

Can you calibrate the tank when the tank is full of water for hydro test
Yes . Once the test is completed you can calibrate the tank full of water,
de-stress the tank to zero stress condition and re-stress the tank for the actual
gravity of the product

What is the impact of gravity in tank calibration

For a given liquid level the hydrostatic pressure is a function of gravity and this
results in tank expansion . If not accounted for it could impact the tank volume
significantly depending on diameter and thickness of shell
Also FR must be compensated for buoyancy that is function of gravity
Gravity of course is needed for VCF

Do you need traceability for working tape calibration

Working tape is calibrated by master tape and master tape is calibrated per National
Standards

Calibration Process Parameters

Following operational parameters must be supplied by the tank owners
to the calibration contractor
Product Temperature
Product Gravity
Roof Leg Position for FR ( Critical Zone: Figure 1)
Zone needed for FR to float fully from rest position (no custody gauging
in this zone)
Ambient Temperature
Maximum Fill Height ( depends on safety rules)

These must not be decided by or assumed by the calibration contractor

Note: Critical Zone Position varies with FR position

Roof Legs

CZ

Floating Roof

CZ

FR in Maintenance Position

FR in Operating Position

Floating Roof Position

Figure 1

Calibration by Manual Method

Manual Method
API Chapter 2.2A
Often is referred to as the Referee Standard (basis for all other methods)
Circumference measured with a working tape at various courses
Working tape is Calibrated against a master tape and applicable tension determined
for actual application
Master tape readings generally are at 68 deg F
Tape is maintained physically in perfect contact with shell
Tape is maintained in horizontal plane
Stroke the straps two or thee times to ensure perfect contact with the shell
Single strap or multiple straps may be used
Multiple straps with a smaller length tape are preferred as they are easy to handle
They are easy to maintain control, contact with shell and horizontality
All circumference measurements are external
Tank shell surface must be clean
8

Field Measurements-1
Calibration in the field involves following physical measurements
Circumference measurement of each course (Figure 2)

Using working tape calibrated with appropriate tension

Multiple straps or single strap at each course
Typical tape length of 100 ft may be used
Number of Straps required = * D( ft )

Plate Thickness

100( ft )

Measured ultrasonically all around in each course (8 to 12 data points) and

averaged for each course

Diameter
Computed from the measured circumference and the thickness

Note: Ideally scaffolding fixed or portable needed to maintain tape in contact

with shell

48 to 64 ft

AB, BC, CA : Three straps (An example)

A to A : Single Strap (heavy)
Multiple Straps easier to handle

Manual Calibration : API Chapter 2.2A

Figure 2

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Field Measurements-2
Reference height and reference gauge point (Figure 3)
Critical component of calibration
For new tanks easily established
For old tanks the bottom access to datum plate may not be possible as bottom
maybe filled with solid sludge or other foreign materials
If access is not available one should not try and measure RH but use the
RH from previous calibration table
Gauge point is the point from which gauging should be undertaken
The gauge point should be clearly marked on the stilling well

Critical Zone (Figure 1)

On empty tanks roof leg position can be verified physically
On tanks in service , information may be taken from the last tank calibration
table
Typically this is in the range of 6 to 12 in but could be as high as 18 in
depending on FR design
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Field Measurements-2
Deadwood
All internal piping and other structures inside are physically measured and
their volumes distributed vertically from the datum plate
This is necessary to subtract the volume of the deadwood as tank table is
developed (volume Vs height)
This is possible only when entry is permitted into the tank, if not it should be
taken from the most recent calibration data

FR Weight
During calibration FR weight is collected either from old table data or
physically measured and computed. But computation could potentially carry
large uncertainty
Number of welding rods that are used in the FR fabrication must be taken into
account or else could understate the FR deadweight
Best obtained from the fabricator and documentation on file maintained for
all future calibration

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Field Measurements-3

Maximum Shell Height

This height is measured and documented as part of the development of the tank table
Measured externally from the base

Maximum fill Height

Bottom Calibration

Depends on local conditions

Earthquake zones ; 4 to 6 feet below the top rim
Others limited by FR height

Tilt

Tank bottom could be flat, cone up or cone down

Tank bottoms are measured by physical survey when entry is allowed
Tank bottoms may also be calibrated with liquid (water)
When in service the zero gauge volume is copied from old tables

Zero gauge volume is the volume below the datum plate

Measured optically or manually by plumb line

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Capacity Table Development

The capacity table is simply a table that gives the volume of the tank at
any given height
In the development of the table following corrections should be applied

FR buoyancy correction
Tank tilt correction
Hydrostatic correction
Shell temperature correction
Master tape correction
Working tape correction
Other correction such as tape rise

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Corrections 1
FR Buoyancy Correction
Correction is based on gravity of the product and FR weight
FR correction (volume units) must be subtracted from the total volume at any
given level as long as FR is fully floating
In critical zone the FR correction is distributed over the range of the zone
Below the critical zone FR correction is zero
Tank table carries the base FR correction for a given gravity and incremental
correction for variations in base gravity

Tilt Correction
No correction needed when tilt is less than 1 in 70
Tilt correction is requires when tilt exceeds the above value
Maximum tilt should be less than 2.4 in 100

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Corrections -2
Hydrostatic Head correction
Hydrostatic head (liquid pressure) causes expansion of the tank shell
Additional volume from pressure expansion may be as high as 0.08%
depending on plate thickness
Expansion function of plate thickness and gravity for a given tank
API 2.2 A provides detailed procedure for calculating the incremental volume
and the total volume for pressure correction

The additional incremental and total volume is generally included in the

capacity table for a given gravity of the product
Variation in gravity of +/- 5 deg API will have negligible impact on the
computed volume
If the gravity changes by more than 10 deg API the table must be rechecked

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Corrections - 3
Shell Temperature Expansion Correction
Shell expands due the combined effect of product and ambient temperature
The impact on total volume could be 0.05% and higher
The shell temperature determination equation has been modified from the
old API Standard 2550
It is no longer the mean of ambient and product temperature
In the new equation product temperature dominates
Tanks which are insulated, the shell temperature equals product temperature
The temperature expansion factor may be included in the main capacity table
for a give product and ambient condition or
The capacity table may be established at 60 deg F or 15 deg C and the shell temperature
expansion factor may be applied externally for each batch received or discharged from the
tank with actual field temperatures
The capacity table may also be accompanied by a temperature expansion factor table when
the capacity table is at 60 deg F

18

Corrections - 4
New Shell Temperature Equation
7 * TL + TA
8
TL = Liquid Temperature
TS =

TA = Ambient Temperature

Master Tape Correction

Tape carries calibration to 68 deg F
Measured lengths should be corrected to 60 deg F

Other Corrections
Tape rise correction, if needed, should be applied

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Recalibration Frequency

Informative Appendix in API Chapter 2.2 A provides guidelines

Recalibration is required on all tanks if internals are modified
Recalibration may also be mandated by local regulations or customs
Recalibration is required if the tank bottom repair work is undertaken

5/15 rule for tanks in Custody Service

Bottom course verified once every 5 years for diameter, thickness and tilt
Variations in D, t, and tilt (from previous calibration) are computed and impact
on volume determined
If variation in volume is in excess of 0.02% recalibration is recommended
If variation in volume is within 0.02% , 5 year verification is continued until 15
years when total recalibration is recommended

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Working Tape Re calibration

Working Tape should undergo re calibration after application on 20 tanks,
once every 20 tanks
Working tape should undergo re calibration if it is to be used on a tank or
tanks whose circumference(s) vary by more than 20% the circumference
of the tank on which the tape was originally calibrated
Master tape should be re certified once every two years .

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Re Computation
Re computation/Verification of table required when gravity changes by 10
deg API or higher
Diameters from the last calibration may be used to compute the new volumes
for gravity changes

Re computation required when average product temperature has changed

by 20 deg F or higher (if the temperature correction is built into the table)
Capacity table revised to reflect New RH if the stilling well is extended on
top with a nozzle for alternate gauging devices.

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Capacity Table and Raw Field Data

All raw data collated in the field should be made available to the tank
owner along with main capacity table
Capacity table should generally contain following information at the very
minimum:

Product ID, RH, Nominal Diameter

Product Gravity, Product temperature
Critical Zone
FR total and incremental correction
Shell Temperature correction table if capacity table at 60 deg F

Appropriate foot note if corrections are already built into the table

RH and Reference gauge point location

Method of calibration and date of calibration
Certificate of calibration of working tape and master tape
Signature of the certifying authority
API Standard number (e.g. 2.2A) used in the calibration
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Optical Reference Line Method (ORLM)

Reference Standard: API Chapter 2.2B
This method establishes diameters of the courses by optical method
The method can be applied internally or externally (external easier)
Procedure (Figure )

Tank divided into horizontal and vertical stations

Number of stations horizontally vary from 8 to 36 depending on diameter
Magnetic trolley with graduated scale moved vertically
Reference circumference of bottom course by manual method (API Chapter 2.2A)
Reference offset is measured optically at the same height where the reference
circumference is measured
At each horizontal station, course offsets are measured (Two per course) optically
Deviations in course offsets from the reference offset are averaged for each course
Using the reference circumference and deviations the course diameters are
established

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E
F

D
Optical Device

A
HORIZONTAL STATIONS
OPTICAL REFERENCE LINE METHOD

A , B .Horizontal Stations

Optical Reference Line

A

B
Vertical Station:Typical

Optical Reference Line

h/5

NOTE: Plan view shown for 8 stations

Course Height h
h/5
Weld Seam
Magnetic Trolley
Reference Diameter

Scale
Reference Offset

300 mm

Optical Device

Optical Reference Line Method (ORLM)

Figure 4

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ORLM

Important Considerations

Optical device stability is critical

Device must be in level in all directions
The optical ray must be vertical throughout the height of the tank (within
limits)
At each station reference offset is rechecked b after the full vertical traverse
The optical device is checked randomly at three locations for perpendicularity
by rotating the device 360 deg
In extreme windy condition , when it is difficult to maintain the trolley in
contact with the shell, calibration should not ne undertaken
Other Measurements
Identical to manual method API Chapter 2.2 A
Development of the Capacity table
Per API Chapter 2.2A
Advantages
Much easier, no scaffolding and reference circumference is easier to control
being at the base
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Optical Triangulation Method (OTM)

Reference Standard : API Chapter 2.2 C
This method establishes diameters of the courses by optical method
The method can be applied internally or externally (internal easier)
Procedure (Figure 5)

Tank is divided into horizontal and vertical stations for both internal and external
methods
Tank profile is established by triangle at each target point and hence the name
OTM
For internal method reference distance D is established optically using
temperature compensated Stadia typically 2 m long
Subsequently tank coordinates A(x, y) are measured optically using two
theodolites
For external method the tangential angles are measured along with the distance
between the two theodolites ( T1 T2 )
Diameters are computed using mathematical computational procedures
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X
T, L = Theodolites

A(X,Y) : Coordinates

T1

A(x, y)

D
T2

+
*

* A2

AN

Target Points
(A1..AN)

T1 , T2 . For External Calibration

TD, For Internal Calibration

Ring 3

*
A1

A1, A2.AN Horizontal Stations

D = Reference Distance
, : Coordinate Angles

Ring 2

h/5

A1

A2

AN
Ring 1

h/5

Vertical Stations

OTM: Internal and external

Figure 5
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OTM
Important Considerations
Optical devices stability is critical
Devices must be in level in all directions
Distance D for internal method should be measured again at the end

Other Measurements
Identical to manual method API Chapter 2.2 A

Development of the Capacity table

Per API Chapter 2.2A

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Electro Optical Distance Ranging Method

(EODR)

Reference Standard: API Chapter 2.2 D

This method is for Internal application only
Like ORLM and OTM the method establishes diameters of all courses
Procedure (Figure 6)

Establish a reference target on the bottom course and note the reference distance
and reference angle
Spherical coordinates are measured using distance ranging device (r, , ) for each
target point
Tank profile is thus established from bottom to top
The reference distance of the target and the reference angle of the target at the
end are rechecked
Using standard mathematical procedures, diameter of courses is computed
With an on line computer, diameters can be determined instantaneously
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r, , : Spherical Coordinates
: Vertical angle
: Horizontal angle to reference target

Target Points

Ref. Target

Optical Device

Electro Optical Distance Ranging Method : EODR

Figure 6
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EODR
Important Considerations
Optical device stability is critical
Device must be in level in all directions
The measurements at the reference target at the end of the tank traverse
should be repeatable

Other Measurements
Identical to manual method API Chapter 2.2 A

Development of the Capacity table

Per API Chapter 2.2A

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Liquid Calibration

Reference Standard: API Standard 2555

Level Vs Volume is established directly
Volume Q1 is metered ( volume through meter that is calibrated prior to start of the tank
calibration) and corresponding level L1 is measured
Increments will depend on tank diameter and generally should be 6 in to a foot
Recalibration of the meter at the conclusion is required
In liquid calibration hydrostatic correction is not necessary as at each level the tank is
already in an expanded state
Alsothe deadwood correction is not necessary
RH must be measured per API Chapter 2.2A
Liquid used: Product to be stored in tanks or water
If water is used, then adjustments to the volume by courses is necessary due to the
gravity variation between water and the product
Time consuming and may take as much as two days
This standard is an old standard and will be revised in future

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Conclusions

Tank calibration is a must for custody transfers, mass balance in refineries and
volume balances in tank farms and pipeline terminals

Tank fabrication drawings should not be used for determination of tank diameter.

Recalibration at set frequency is equally important

Any of the methods presented herein may be used to establish tank diameters

Tank calibration should never be undertaken over insulation in insulated tanks

For Insulated tanks, internal calibration or liquid calibration may be used if
insulation cannot be removed
If insulation can be removed, external calibration may be used

Shell expansion due to hydrostatic pressure and expansion due to temperature are not
negligible and must be included in the development of the capacity table

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