Group Practice

GP 58-10

Above Ground Welded Steel Atmospheric Storage

Tanks

14 February 2011
Engineering Technical Practice
Engineering
Above Ground Welded Steel Atmospheric Storage Tanks

Table of Contents
Page
Foreword.......................................................................................................................................... 4
1 Scope...................................................................................................................................... 5
2 Normative references.............................................................................................................. 5
3 Terms and definitions.............................................................................................................. 6
4 Symbols and abbreviations.....................................................................................................8
5 General design considerations................................................................................................9
5.1 Design life.................................................................................................................... 9
5.2 Design codes............................................................................................................... 9
5.3 Environmental requirements.........................................................................................9
5.4 Design aspects for corrosion mitigation......................................................................10
5.5 Corrosion allowance (CA)..........................................................................................10
5.6 Cathodic protection (CP)............................................................................................10
6 Selection of tank and roof type..............................................................................................11
7 Specific design considerations..............................................................................................12
7.1 General...................................................................................................................... 12
7.2 Fixed roof tanks.......................................................................................................... 15
7.3 External floating roof tanks.........................................................................................17
8 Hydrotesting.......................................................................................................................... 24
9 Coatings................................................................................................................................ 24
9.1 General requirements.................................................................................................24
9.2 Internal coatings - additional considerations...............................................................24
9.3 External coatings - additional considerations.............................................................25
10 Thermal insulation................................................................................................................. 25
10.1 General requirements.................................................................................................25
10.2 Corrosion under insulation (CUI)................................................................................25
11 Instrumentation..................................................................................................................... 26
11.1 General requirements.................................................................................................26
11.2 Overfill protection.......................................................................................................26
11.3 Over temperature protection.......................................................................................27

Copyright © 2011 BP International Ltd. All rights reserved.

This document and any data or information generated from its use are classified, as a
minimum, BP Internal. Distribution is intended for BP authorized recipients only. The
information contained in this document is subject to the terms and conditions of the
agreement or contract under which this document was supplied to the recipient's
organization. None of the information contained in this document shall be disclosed
outside the recipient's own organization, unless the terms of such agreement or contract
expressly allow, or unless disclosure is required by law.

In the event of a conflict between this document and a relevant law or regulation, the
relevant law or regulation shall be followed. If the document creates a higher obligation, it
shall be followed as long as this also achieves full compliance with the law or regulation.

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11.4 Tank gaging requirements..........................................................................................27

Annex A (Informative) Guidance on tank corrosion for design........................................................28
A.1. General................................................................................................................................. 28
A.2. Underside corrosion of floor plates........................................................................................28
A.3. Topside corrosion of floor plates...........................................................................................29
A.4. Corrosion of shell plates........................................................................................................29
A.5. Corrosion on fixed roofs and support structures....................................................................30
A.6. Corrosion on roof plates of external floating roofs, including supporting legs........................30
Annex B (Informative) Floating roof seals.......................................................................................30
B.1 Internal floating roof seal.......................................................................................................30
B.2 External floating roof seal......................................................................................................30
Bibliography................................................................................................................................... 30

List of Tables

Table A.1 - Typical tank sand specification.....................................................................................29

List of Figures

Figure 1 - Typical internal floating roof installation in a fixed roof tank (from API RP 575, by
permission of the American Petroleum Institute)...................................................................16
Figure 2 - Typical single deck annular pontoon external floating roof construction (from API RP 575
by permission of the American Petroleum Institute)..............................................................18
Figure 3 - Typical double deck external floating roof construction (from API RP 575 by permission
of the American Petroleum Institute).....................................................................................18
Figure 4 - Typical installation for seal plates, foam dams, poles, and ladders................................19
Figure B.1 - Primary shoe seal with secondary wiper seal.............................................................30
Figure B.2 - Secondary seal made from sheet metal......................................................................30
Figure B.3 - Double compression plate seal and integral foam dam for external floating roof........30

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Foreword

This is the firsta revised issue of Engineering Technical Practice (ETP) GP 58-10. This Group Practice
(GP) is based on partsincorporates the addition of heritage documents from the merged BP companies
as follows: Annex B.

British Petroleum

RP 58-1 Non-refrigerated Petroleum and Petrochemical Storage.

GS 158-1 Internal Floating Decks for Storage Tanks.
GS 158-2 Vertical Storage Tanks for Non-refrigerated Liquids.

Amoco
A FE-TK-00-E Fabricated Equipment - Tanks - Engineering Specification.
A FE-TK-650B-P Fabricated Equipment - Tanks - API 650, Appendix B, Foundation
Procurement Specification.
A FE-TK-650E-P Fabricated Equipment - Tanks - API 650, Appendix E, Seismic Design
Procurement Specification.
A FE-TK-650H-P Fabricated Equipment - Tanks - API 650, Appendix H, Internal Floating
Roofs-Procurement Specification.

ARCO
ES 900-97 Welded Oil Storage Tanks.

Changes to this document are indicated by a bar in the left margin.

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1 Scope

a. This GP provides requirements and guidance for field erected above ground vertical
cylindrical welded steel atmospheric storage tanks within the scope of the referenced
design codes.
b. The following types of tanks are outside the scope of this GP:
1. Storage tanks for refrigerated or cryogenic liquid service.
2. Underground or in ground storage tanks.
3. Spheres and spheroids.
4. Rectangular steel tanks.
5. Bolted and riveted tanks.
c. Requirements for the following storage tank design aspects are outside the scope of this
GP:
1. Tank layout and bunding (GP 44-10 is applicable).
2. Foundations (GP 04-60 is applicable [GP 04-60 is in development and not currently
available]).
3. Secondary containment and leak detection systems external to the tank (GP 04-60 is
applicable [GP 04-60 is in development and not currently available]).
4. Fire protection (GP 24-40 is applicable).
5. Earthing (grounding) (GP 12-25 is applicable).
d. This GP does not provide guidance on storage tank operations or in-service inspection,
maintenance, or modifications.

2 Normative references

The following referenced documents may, to the extent specified in subsequent clauses and normative
annexes, be required for full compliance with this GP:

• For dated references, only the edition cited applies.

• For undated references, the latest edition (including any amendments) applies.

BP
GIS 58-101 Welded Steel Atmospheric Storage Tanks (API 650).
GP 06-25 Design for the Prevention of Corrosion under Insulation and Fireproofing
(CUI and CUF).
GP 06-60 Painting of Metal Surfaces.
GP 06-63 Internal Coatings.
GP 06-67 Design Decisions That Affect Corrosion.
GP 12-25 Earthing (Grounding).
GP 24-40 Fire Protection of Atmospheric Storage Tanks.
GP 30-25 Field Instruments - General.
GP 48-03 Layer of Protection Analysis (LOPA).
GP 52-10 Thermal Insulation.
GP 64-03 Static Fluid Measurement Systems.

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Air BP
GEN 511 Product Quality Standard for Handling Aviation Fuels at BP Refineries.

American Petroleum Institute (API)

API RP 575 Inspection of Atmospheric & Low Pressure Storage Tanks.
API RP 651 Cathodic Protection of Aboveground Storage Tanks.
API RP 2350 Overfill Protection for Storage Tanks in Petroleum Facilities.
API Std 650 Welded Tanks for Oil Storage.

European Standards (EN)

EN 14015 Specification for the design and manufacture of site built, vertical,
cylindrical, flat-bottomed, above ground, welded, steel tanks for the
storage of liquids at ambient temperature and above.

3 Terms and definitions

For the purpose of this GP, the following terms and definitions apply:

Annular plate
Tank bottom peripheral plate supporting shell and to which shell is welded.

Antirotation device
Guide pole(s) or cable system fixed to shell through pontoon of floating roof to prevent rotation.

Articulated drain
Floating roof internal drainpipe made of hard pipe with articulated swivel joints.

Bitsand
Bitumen or oil mixed with sand, used for supporting floor and removing stress raisers.

Bottom
Floor of tank.

Bunding
Arrangement of bund wall or dike enclosing area around tank to provide secondary or tertiary
containment.

Coating
Layer painted or otherwise applied to surface for corrosion protection.

Cone up/cone down

Preformed shape of tank floor bottom.

Corrosion allowance (CA)

Thickness of material that can safely be allowed to corrode, having regard for operating environment
and applied stresses.

Curb angle (top angle)

Reinforcement angle welded at top of shell.

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Design life
Period during which item or component is intended to remain fit for service under specified design and
operating process conditions.

Dipping
Measuring product level in tank.

Dome roof
Type of self supporting steel fixed roof.

Double bottom
Tank with two separated floors to provide means of positive leak detection of the upper floor.

Double deck floating roof

Floating roof structure with top and bottom deck and bulkheads forming compartments.

Emergency drain
Drain installed at lowest point of double deck external floating roof designed to discharge rain water
directly into the product in the event that the primary drain is inoperative.

Floating suction
Suction pipe that floats near surface of product.

Frangible roof
A fixed roof in which the roof to shell joint will fail prior to the shell to bottom joint under excessive
internal pressure.

Guide pole
Pole fixed to top and bottom of tank to guide floating roof.

Hose drain
Floating roof drain system constructed of flexible hose.

Pontoon
Buoyancy chambers or devices for floating roofs.

Primary seal
Main sealing device between floating roof and tank shell. The only sealing device or the lower device
in a double seal arrangement.

Rim seal
Floating roof peripheral seal.

Roof drain
Device to remove accumulating water from external floating roof deck.

Roof support leg

Support leg on external or internal floating roof.

Sampling device
Device to allow product sampling.

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Secondary seal
Additional peripheral seal between floating roof and tank shell to prevent vapour loss and rainwater
ingress and deterioration of the primary seal.

Shell
Cylindrical wall of tank.

Shunt
Metal electrical connection between floating roof and tank shell, located on floating roof.

Stilling well/gage pole

Pipe in which dipping device travels up and down.

Sump
Well for drainage in tank bottom or floating roof deck.

Ullage
Free available capacity in a tank.

Vendor
Person or organisation responsible to BP for design and/or supply of goods or services for project or
installation.

4 Symbols and abbreviations

For the purpose of this GP, the following symbols and abbreviations apply:

BAT Best available technology.

CA Corrosion allowance.

CP Cathodic protection.

CUI Corrosion under insulation.

EFRT External floating roof tank.

GRE Glass reinforced epoxy.

HDPE High density polyethylene.

HSSE Health, safety, security, and environment.

LOPA Layer of protection analysis.

TVP True vapour pressure.

UV Ultraviolet.

VOC Volatile organic compound.

5 General design considerations

5.1 Design life

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5.2 Design codes

a. Tanks shall be designed in accordance with API Std 650 or EN 14015.
b. Tanks designed to API Std 650 shall meet the additional requirements of GIS 58-101.
c. Use of codes other than API Std 650 and EN 14015 shall be subject to approval by the
entity EA.

5.3 Environmental requirements

a. Tanks shall comply with applicable local, regional, or national environmental regulations.
b. Requirements for emissions control are normally covered by the use of BAT. In
constructing a new facility or upgrading an existing facility, the BAT should be identified
and may be used.
c. In absence of local or national regulations, BP local, regional, and/or Group environmental
authority should be consulted.

5.4 Design aspects for corrosion mitigation

a. Mechanical and materials design features to mitigate in service corrosion that are
appropriate for the tank duty and location shall be identified in accordance with GP 06-67.
b. If applicable, use of corrosion resistant materials and coatings for jet fuel tanks shall
comply with Air BP GEN 511.
c. Zinc rich (galvanised) coatings, cadmium alloys, and cadmium plating shall not be
specified for applications in contact with aviation fuels.

5.5 Corrosion allowance (CA)

Required CA, if any, will be specified by BP responsible engineer.

5.6 Cathodic protection (CP)

a. Requirements for external CP should be evaluated on an individual tank basis, depending
on soil conditions, tank foundation design, and local tank corrosion history.
b. Despite recommendations within some standards to install CP on every new tank, careful
consideration should be made to alternative corrosion preventive measures.
c. If CP is the most appropriate means of preventing underside corrosion, API RP 651 is
considered the most up to date applicable code relevant to new construction of above
ground storage tanks. BP corrosion specialists should be consulted for advice on any
additional requirements or exceptions to this code.
d. In some locations, external CP for new tanks may be a regulatory requirement. In these
cases, full evaluation shall be performed and CP design developed to suit local conditions.
e. Internal CP may be considered for tanks with corrosive water bottoms.

6 Selection of tank and roof type

a. Unless required otherwise by applicable environmental regulations, tank type (i.e., type of
roof construction) will be specified by BP, based mainly on TVP and flash point of liquid
under actual storage conditions, as specified on the data sheet and in accordance with
GP 24-40.
b. Additional factors for consideration of tank type relate to local climatic, seismic, and
geological conditions.

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c. Fixed roof tanks may be used for storage of low volatility materials with TVP less than
100 mbara (1,5 psia) under all operating conditions, if the tanks comply with construction
codes and environmental regulations.
d. U.S. regulations require floating roofs for TVP above 52 mbara (0,75 psia). Local
regulations should be checked for applicable limits.
e. In locations with heavy snowfall or extreme rain storms, tanks shall preferably be fixed
roof tanks with internal floating decks rather than external floating roof design.
f. If TVP is between 100 mbara and 750 mbara (1,5 psia and 11,1 psia), inclusive, tanks shall
have external or internal floating roof.
g. If there is a high level of seismic activity, damage may occur to a floating roof that may
not be sustained by a fixed roof tank. Tank design codes do not currently provide guidance
in this aspect of seismic design. Specialist advice should be sought, including an
assessment of the benefit of a double deck versus single deck roof.
h. If TVP is greater than 750 mbara (11,1 psia), tank should have a vapour recovery system.
Otherwise, storage in low pressure vessels or refrigerated tanks should be considered.
i. If an internal floating roof is required in a fixed roof tank with column support, foundation
design should eliminate excessive settlement.

7 Specific design considerations

7.1 General

7.1.1 Tank dimensions

a. Tank dimensions or capacity should be based on facility needs. Exact dimensions should
be determined, based on the site that is available, local conditions, and applicable codes
and regulations.
b. Tank dimensions shall comply with firefighting requirements in GP 24-40.
c. In selecting tank dimensions, the tallest tank compatible with allowable ground loading,
economic fabrication, and local authority restrictions should normally be chosen. Specific
attention should be given to minimising quantity of inaccessible oil in tank when it is at
low working level.
d. Working capacity
1. Working capacity of fixed roof tanks may be estimated by assuming dead space at
bottom will extend 150 mm (6 in) above suction branch, with ullage space of 150 mm
(6 in) if tank is full.
2. Consideration should be given to fitting downturned suction nozzle inside tank to
minimise unusable volume at minimum dip.
3. Working capacity of heated fixed roof tanks should be based on minimum dip of 1 m
(3 ft) above steam coil.
e. To diminish unusable volume under floating roof, the following should be considered
during design stage:
1. Minimising operating height of roof support legs.
2. Smaller multiple inlet/outlet nozzles or nozzles fitted with transition neck from round
to low height section.
3. Mixer blade recesses in floating roof.
4. Internal guides at shell manholes to protect roof seal.

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5. Minimising space required for roof drainage piping.

6. Adequate horizontal clearance between pantograph weights and shell penetrations.

7.1.2 Tank bottom configuration

a. Factors that affect configuration of the tank bottom are:
1. Product being stored.
2. Costs of tank and foundation.
3. Tank volume.
4. Operation of tank and interconnected facilities.
5. Ease of tank cleaning.
6. Water drawoff requirements.
7. Leak detection requirements.
b. If positive leak detection through the floor is required, double bottom tanks may be
considered.

7.1.3 Fittings
Consideration should be given to:
a. Requirements for floating suction.
b. Number and location of floor sumps.
c. Requirement for flush bottom cleanout fitting.
1. Flush bottom cleanout fitting should be provided only if tank cleanup operations can
clearly justify need.
2. In such instances, a minimum standard opening size that will properly accomplish the
purpose should be provided.
3. In remaining cases, if tanks will contain relatively clean liquids, small amount of
bottom settlings can be removed through shell access manholes.
d. Size and number of shell and roof manholes.
e. Requirement for hydrocarbon sensing valves on water drawoffs.

7.1.4 Earthing (grounding)

a. Earthing (grounding) shall comply with GP 12-25.
b. Tank design lightning protection systems shall be separate from tank earthing (grounding)
systems.
c. In designing earthing (grounding) systems, special attention should be given to tank
accessories (e.g., level gages and high level shutdown systems).

7.1.5 Wind load during erection

Consideration should be given to the need for installation of temporary wind girders or other
means of stiffening during tank erection.

7.2 Fixed roof tanks

7.2.1 General
a. Frangible roofs shall be used, if possible.

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b. To ensure pressure tightness of pressure vent valve, tank gas operating pressure should not
be greater than 75% of valve set pressure.
c. Unless specified by BP responsible engineer, fixed roof tanks should not have flame
arrestors.
d. Selection of roof type depends on tank diameter and nature of product. Selection is
generally by vendor. BP may have no particular preference.

7.2.2 Internal floating roofs

a. Type of internal floating roof will be specified by BP responsible engineer. A typical
installation is shown in Figure 1. Seal design for an internal floating roof is discussed in
Annex B.
b. For minimum emissions, internal floating roof should be in full contact with product.

Figure 1 - Typical internal floating roof installation in a fixed roof tank (from API RP 575, by
permission of the American Petroleum Institute)

c. Designs for consideration shall include:

1. A metal floating cover supported by liquid tight metal floating devices that provide
buoyancy to prevent the liquid surface from being exposed if half of the flotation is
lost.
2. A closed top pontoon or double deck metal floating roof.
3. Proprietary designs, such as GRE foam sandwich constructions with proven track
record.
d. Aluminium or GRE of honeycomb construction should not be specified.
e. Suspended cable decks may be considered for lightweight construction.
f. If decks are of bolted construction, assurance shall be required that design and installation
methods will not result in joint leaks.

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7.3 External floating roof tanks

7.3.1 General
a. Single deck roofs shall be limited to a maximum of 85 m (279 ft) diameter. Lower limits
should be considered for severe weather locations. Typical single and double deck
constructions are shown in Figure 2 and Figure 3.
b. Roof and rim seals should be designed to allow accidental tank overflow without any
obstacle to upwards or downwards travel. No appurtenances should project inwards from
the top shell that would collide with the roof or seals in event of overfilling. Otherwise,
there will be a potential source of ignition.

Figure 2 - Typical single deck annular pontoon external floating roof construction (from API RP 575
by permission of the American Petroleum Institute)

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Figure 3 - Typical double deck external floating roof construction (from API RP 575 by permission of
the American Petroleum Institute)

7.3.2 Rim seals

a. Double rim seals should be specified. Seal design is discussed in Annex B.
b. Stainless steel secondary seal plates should be specified for corrosive environments. The
primary seal plates may be stainless steel or galvanised carbon steel, because they are not
exposed to the atmosphere. Figure 4 shows a typical installation.

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Figure 4 - Typical installation for seal plates, foam dams, poles, and ladders

7.3.3 Pontoons
a. Top edge of bulkheads (compartment plates) shall be continuously welded.
b. If floating, entire roof surface should be in contact with liquid to eliminate vapour space.
c. Pontoon type floating roof should be proportioned such that, if floating, product level is
approximately 40 mm (1 1/2 in) above level of single deck.
d. Single deck shall be designed to provide good drainage of rainwater.
e. Bleeder vents
1. Roof shall have adequate bleeder vents to land roof for maintenance and to fill tank
after maintenance.
2. Bleeder vents/vacuum breakers shall be designed in accordance with applicable
standards to prevent formation of a pressure differential across the deck during initial
filling or final emptying of the tank while the roof is landed.
3. Bleeder vents usually operate in concert with roof supports. Bleeder vent position
should be adjusted if position of roof supports changes. Failure to do so can cause
vacuum under roof, resulting in serious overstressing.
f. Pontoon area shall have good drainage.

7.3.4 Roof drains

a. Main drain may be articulated steel, bonded hose, or unbonded flexible pipe construction.
b. For small diameter tanks and tanks in locations of minimal rainfall, a single drain will
probably be adequate. Two or more drains should be provided for:
1. Larger diameter tanks, for which exceptional rainfall may be expected.
2. Critical duties, for which maximum tank reliability is required.

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c. Network of “satellite” secondary drains that feed to centre sump for main drain should not
be specified.
d. Double deck roofs should have emergency drains.
e. Consideration should be given to specifying hydrocarbon sensing valves on roof drain
outlets.

7.3.5 Still wells/antirotation poles

The following points should be considered:
a. Number of still wells/poles should be minimised. A single pole with dual function should
be considered. Two poles, if required, should be placed close together, as shown in
Figure 4.
b. Still well design
1. Still wells or gage poles may have drilled or slotted holes.
2. The interior of the still well, whether holes or slots, shall be deburred to prevent float
hang up or false radar returns.
3. Nonperforated still wells may eliminate wind induced emissions, but use of still well
for representative sampling and accurate level gaging is no longer possible. At some
locations, regulatory bodies require nonperforated still wells. In these cases, sampling
and gaging should be performed through gasketed roof hatch.
4. If compliance restrictions allow, one option for reducing emissions is to replace
existing slotted still well with one having round holes. Holes should be large enough
to prevent choking with viscous stocks and number fewer than conventional slots.
5. No practical data are available on how representative sampling through still wells of
this design may be. Therefore, it is advisable to use another location for this activity
(e.g., gaging hatch) if site safety regulations allow.
6. Practical and theoretical observations show that wind flow is parallel to tank shell if
in close proximity. As such, there are benefits to positioning still well slots/holes
facing the tank shell. Locating slots/holes diametrically opposite each other should be
avoided.
c. Sliding covers.
d. Still well sliding cover with sleeve should be installed to comply with applicable
environmental requirements.
e. Still well floats.
1. Further reductions in still well emissions can be achieved by using float to cover
liquid surface within the still well. The still well float should extend above liquid
surface to level at least as high as sliding cover. This is stipulated by regulatory
authorities in some locations.
2. Introduction of float in the still well inhibits manual gaging and sampling.
f. Still well equipment should have wipers.

7.3.6 Roof support legs

a. Adequacy of roof support leg designs and associated safety factors shall be assessed.
b. Consideration should be given to differential floor settlement during erection and
operation. During operation, it is possible that all legs will not be in contact with the
supporting floor or may not be vertical.

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c. Design assumptions should be agreed upon with BP responsible engineer and clearly stated
in the design documentation.
d. Legs/sleeves should have seals to minimise vapour loss.

7.3.7 Rolling ladders

a. Requirements for provision of rolling ladders shall be assessed in accordance with
GP 24-40.
b. If no ladder is provided, an alternative earthing (grounding) cable arrangement shall be
required (e.g., a coiling mechanism mounted on the top shell to accommodate roof
movement).

8 Hydrotesting

Consideration should be given to the available source, capacity, quality, and disposal of
hydrotest water.

9 Coatings

9.1 General requirements

Coatings shall comply with GP 06-60 and GP 06-63, whichever is applicable.

9.2 Internal coatings - additional considerations

9.2.1 All tank types

a. Requirements for coatings should be assessed, based on local history of tanks in equivalent
service, if possible.
b. Coating requirements for tanks in jet fuel service should be separately assessed.
c. Tanks in duties for which a corrosive water or sludge bottom can be expected to be present
should be internally coated as follows:
1. Floor and associated fittings.
2. 1 m to 1,5 m (3 ft to 5 ft) up shell, depending on duty and depth of anticipated
water/sludge level.

9.2.2 Fixed roof tanks

Underside of fixed roof tanks, including roof supporting structure and top nonwetted section of
the shell, may require coating, depending on corrosivity of the vapour in the vapour space and
the need to maintain product cleanliness.

9.2.3 External floating roof tanks

a. EFRTs in light product service may require internal coating of the complete shell,
especially in warm humid environments.
b. EFRTs may require internal coating to the top section of shell, due to nonwetting by
hydrocarbon, depending on local atmospheric corrosivity. If internal shell coatings are
specified for EFRTs, consideration should be made of the implications for earthing
(grounding) of the floating roof to the shell.
c. Internal surfaces of EFRT pontoons should not be coated.
d. Underside of EFRT roof and pontoons will not normally require coating, because they
should be permanently wetted by the product.

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9.3 External coatings - additional considerations

Tank external steel surfaces should be painted as follows:
a. Shell and appurtenances.
b. Roof, pontoons for EFRTs, and associated appurtenances. Particular consideration should
be given to coating the pontoon rim plate of EFRTs (i.e., the vertical plate adjacent to the
shell and rim seal).
c. External coating of insulated tanks to prevent CUI shall comply with GP 06-25.

10 Thermal insulation

10.1 General requirements

Thermal insulation shall comply with GP 52-10.

10.2 Corrosion under insulation (CUI)

a. Design details in GP 06-25 to mitigate risk of CUI shall be followed.
b. Use of cellular glass with closed cells that have low moisture retention properties is
recommended for such areas as bottom section of shell.
c. Care should be taken to select appropriate adhesives and sealants, since aging of adhesives
and sealants may allow water ingress between insulation and shell, causing severe
corrosion that cannot be detected.
d. Heating coil penetrations in the bottom section of the shell should have annular pipes to
separate insulation from nozzles to prevent accelerated corrosion at these spots.
e. Penetrations
1. Penetrations through insulation weatherproofing should be minimised.
2. Penetrations (e.g., curb to roof connection) should be well sealed to prevent rainwater
from running between insulation and shell.
3. Regular inspection and maintenance is necessary to keep weatherproofing watertight.
f. Proper walkways to prevent personnel from walking on insulation are essential.
g. In addition to bottom of tank, insulated shell wind girders and other stiffening rings are
vulnerable areas.
h. On fixed roofs, it may be better to coat roof rather than insulate.
i. If the tank is insulated, the roof and shell should have pockets to allow routine
measurement of thickness by ultrasonics.
j. If supports are poorly designed, attachments used for supporting insulation may create
water traps, giving rise to localised corrosion.

11 Instrumentation

11.1 General requirements

Instrumentation shall comply with GP 30-25.

11.2 Overfill protection

a. Tanks shall have continuous level measurement, with a span selected to indicate the full
operating volume of the tank. The device shall have a high level alarm.

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b. The tank high level alarm set point shall be selected to provide adequate time for the
operating team to take action to prevent overfill. Refer to API RP 2350.
c. Tanks should have independent secondary measurements, providing a second
(independent) high level alarm.
d. The need for further overfill protection shall be determined by completing a LOPA in
accordance with GP 48-03.

11.3 Over temperature protection

Consideration should be given to providing heated tanks with high temperature alarms or trips
of the heating supply.

11.4 Tank gaging requirements

a. Tank gaging shall comply with GP 64-03.
b. Tank gaging shall comply with applicable regulatory requirements (e.g., customs and
excise).

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Annex A
(Informative)
Guidance on tank corrosion for design

A.1. General

a. EEMUA 159 provides data on typical corrosion rates that can be used to indicate
requirements for coating or a corrosion allowance. However, local conditions vary, and no
specific requirements can be mandated. In general, local experience will be the best guide,
supplemented by wider experience from the BP Group, as needed.
b. Additional guidance on typical types, locations, and rates of corrosion is provided in this
Annex.

A.2. Underside corrosion of floor plates

a. General underside corrosion of bottom plates should be slight, if foundation is well

prepared and maintained, typically, 0,125 mm/yr (5 mil/yr) for carbon steel. However,
problems of severe attack are common, though not always for same reasons. Pitting
corrosion is particularly serious, as this may grow faster than general corrosion.
b. Main causes of underside corrosion are as follows:
1. Poor drainage around tank and water collecting around tank and migrating under
bottom.
2. Mill scale on underside of tank floor plates.
3. Tank settlement that lowers tank below level for adequate drainage. This may lead to
corrosion of annular plate around tank perimeter. Corrosion may be severe adjacent to
shell but is generally restricted to approximately 1 m (3 ft) from outside of tank
bottom/annular plates.
4. High groundwater table or underground springs.
5. Coral and beach sand with high chlorides used for foundation, leading to rapid pitting.
6. Acidic coal based cinders, slag, sharp or large stones being included in foundation.
7. Poor quality bitsand (e.g., road mix rather than bitumen rich).
8. For tanks storing heated products, such as asphalt, there are large differences in tank
to soil electrical potential across bottom. This can cause deep random pitting.
Potentials become more anodic from centre of tank outwards. Hot tanks increase
water permeation under bottoms, and corrosion rates increase with increasing
temperature.
9. Stray DC currents, such as from nearby electric railway, may cause extremely high
local corrosion.
10. Failure of protective cuffs placed around protruding external rim of bottom annular
plate. These cuffs can be felt or lead flashing. Outer edge is embedded in tank
foundation and tank shell with bitumen. Embrittlement of seal material, as well as
separation of seal from tank due to movement, allows rainwater to run underneath
tank. Some modern cuff designs are UV light resistant rubber and might perform
better than ones made from felt or lead.
c. To minimise underside corrosion, the following should be considered:
1. Effective drainage away from tank foundation and floor plate (e.g., by adequate
height of foundation above grade and sloping aprons).

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2. Appropriate support material for tank floor. This should be free of vegetation or
organic materials, sharp or large stones, welding slag or weld rods, acidic coal based
cinders or slag, and chloride bearing materials, such as beach sand or coral. See
Table A.1 for a typical tank sand specification.
3. The use of a 50 mm (2 in) layer of oiled (bitumen) sand between the floor of the tank
and a properly prepared foundation and rain shield or seal around the tank annular.
Note that local regulations may impose limitations on the use of oiled sand.
4. Cathodic protection.

Table A.1 - Typical tank sand specification

Sieve size Percent Sand pH Chlorides Sulphates

finer equivalent
mm in or # ppm ppm
9,5 3/8 in 100,0 79 to 80 6,5 to 7,5 < 200 < 200
6,3 1/4 in 99,5
4,75 #4 99,0
2,36 #8 81,0
2,00 #10 76,0
0,85 #20 45,0
0,419 #40 23,0
0,25 #60 10,0
0,15 #100 5,5
0,075 #200 3,0

Cobbles Gravel Sand Silt and Organic Resistivity

clay impurities
0,0% 0,9% 96,1% 3,0% 2,5% or less > 10 k Ohm

A.3. Topside corrosion of floor plates

a. Topside corrosion of bottom plates occurs at low spots where water collects, such as
locations of local settlement. However, because the floor is normally constructed using lap
joints and fillet welds, water can collect virtually anywhere across bottom.
b. Rates of topside corrosion of unprotected bottom plates can be quite high (e.g., 1 mm/yr
[0,04 in/yr] in crude oil service).
c. Corrosion is usually by localised pitting and/or preferential weld attack, often driven by
microbiological activity, especially sulphate reducing bacteria. This is why protective
coatings are more effective than corrosion allowance.
d. Anchor chains from flexible hose drains rubbing on floor, articulated drain attachments,
roof legs, and dipping and sampling devices have also caused accelerated failure.
e. Water drawoff sumps are usually constructed of thicker steel than the rest of the bottom
and are, by their nature, in potentially corrosive service. Protective coating integrity is
important and is facilitated by dished sump designs.

A.4. Corrosion of shell plates

a. Shell side corrosion can occur in solvent, naphtha, and gasoline tanks and for products
with density generally lighter than 50 degree API, if water is present.

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b. For petroleum products heavier than 50 degree API, shell corrosion in liquid phase is
rarely a problem, because oxygen solubility is low and oil filming provides its own
protection.
c. Corrosion in vapour space of fixed roof tanks depends on climate, effectiveness of
protective filming provided by product, and tank filling and emptying schedule.
d. Corrosion may occur on shell above and below liquid level in gasoline and other light
product storage tanks. Below liquid level, there may be general metal waste and pitting
corrosion.
e. Protective scale may be removed by cracking and spalling, due to successive cycles of wet
and dry conditions, changes in temperature, etc.
f. For floating roof tanks, scraping action of roof seal shoes may further accelerate removal
of protective scales and cause vertical grooving of shell.
g. Preferential corrosion at welds is quite common. A galvanic cell is set up if weld metal or
weld heat affected zone is anodic to rest of shell plate. Corrosion rate may be double at
weldments.
h. Corrosion may take the form of uniform loss (general, even wastage of surface area) or
pitted appearance (irregular wastage).
i. Shell corrosion is generally not a problem in floating roof tanks storing crude oil because a
protective film is deposited, although some pitting and general corrosion has been found
on shell plates in areas within 300 mm to 450 mm (12 in to 18 in) above bottom plate. This
is due to water content of stored liquid or rainwater getting past seals to mix with tank
contents.

A.5. Corrosion on fixed roofs and support structures

a. General and/or pitting corrosion can occur on underside of fixed roofs and their support
structures in the vapour space. This is most severe if aggressive products are being stored
in warm humid environments and no internal floating roof is present.
b. Water condenses on metal surfaces in the vapour space, and if the design allows this water
to be trapped, severe corrosion can occur. Condensed water film becomes saturated with
air from tank breathing and with H2S, if present. Corrosivity is generally low in absence of
both air and H2S in the vapour space (e.g., with gas blanketed operation).
c. In severe cases of vapour space corrosion, roof plates have holed through in 2 yr.
Structural members suffer, in particular, at bottom edges of vertical members, at vertical
ends of members (end grain corrosion), and at bolt holes.
d. Dark colour paint on outside increases metal temperatures, and corrosion rates increase
with temperature. Rule of thumb often quoted is that corrosion rates will double for each
10°C to 15°C (18°F to 27°F) temperature rise.
e. Total sulphur content of product stored is not necessarily a guide to corrosivity in the
vapour space. This is governed by free H2S that evolves.
f. Corrosion on outside of roof can be caused by vapours emitted from open vents on roof.

A.6. Corrosion on roof plates of external floating roofs, including supporting

legs

a. Floating roofs are generally constructed from 5 mm or 6 mm (3/16 in or 1/4 in) thick steel
plates.

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b. Poor drainage may result in pools of rainwater on the centre deck. Some pools are almost
inevitable, even with the best constructed tanks.
c. Pooled water, in conjunction with salt spray, sand, or dirt blown onto roof by wind, may
damage the protective paint layer and cause corrosion. Corrosion may, in turn, increase the
potential for fatigue cracking of lap welds and may cause leaks in the centre deck of
pontoon roofs.
d. Corrosion may also develop around roof supporting legs and at the periphery of the centre
deck, where it is welded to annular pontoon.
e. Severe contact corrosion between the roof leg and surrounding sleeve can occur, unless
sufficient clearance is provided. The use of socks to prevent hydrocarbon emissions
between the leg and sleeve will prevent water entry and corrosion in this area.
f. On double deck floating roofs, corrosion of the upper deck will result in water entering
pontoon, with serious implications for further corrosion of uncoated steel inside the
compartments.

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Annex B
(Informative)
Floating roof seals

B.1 Internal floating roof seal

a. A commonly used seal design for internal floating roof is shown in Figure B.1.
b. Primary seal, extending into product, is spring loaded.
c. Secondary seal shown is wiper type and is made of non-metallic materials. Metallic
compression plate designs are also commonly used. These usually comprise stainless steel
with elastomeric seal tips.

Figure B.1 - Primary shoe seal with secondary wiper seal

d. Alternative design has secondary seal made of sheet metal, similar to Figure B.2.

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Figure B.2 - Secondary seal made from sheet metal

B.2 External floating roof seal

Commonly used arrangements for double seals are as follows:

a. A metallic shoe plate primary seal and a compression plate secondary seal similar to
Figure B.2.
b. Primary and secondary seals both of compression plate design as shown in Figure B.3.

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Figure B.3 - Double compression plate seal and integral foam dam for external floating roof

Secondary
wiper seal

Integral
foam dam
Secondary seal
compression plates

Rim clamp for seals

and integral foam dam

Primary seal
compression plates

Primary
wiper seal

Bumper bars

Vapour barrier
skirt and weights

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Bibliography

BP
[1] GP 04-60, Foundations for Onshore Facilities.

[2] GP 06-29, Corrosion Protection During Hydrotesting.

[3] GP 06-31, Cathodic Protection.

[4] GP 30-15, Level Instruments.

[5] GP 44-10, Plant Layout.

American Petroleum Institute (API)

[6] API RP 2350, Overfill Protection for Storage Tanks in Petroleum Facilities.

Energy Institute (EI)

[7] API/EI Standard 1541, Performance requirements for protective coating systems used in aviation fuel
storage tanks and piping.

Engineering Equipment and Material Users Association (EEMUA)

[8] EEMUA 159, Users' Guide to the Inspection, Maintenance and Repair of Above ground Vertical
Cylindrical Steel Storage Tanks.

[9] EEMUA 180, Frangible Roof Joints for Fixed Roof Storage Tanks: Guide for Designers and Users.

Environmental Protection Agency (EPA)

[10] 40 CFR 60 Subpart Kb, 40 CFR Part 60 - Subpart Kb - Standards of Performance for Volatile
Organic Liquid Storage Vessels (Including Petroleum Liquid Storage Vessels) for Which
Construction, Reconstruction, or Modification Commenced after July 23, 1984.

[11] 40 CFR 63 Subpart CC, National Emission Standards for Hazardous Air Pollutants From Petroleum
Refineries.

National Fire Protection Association (NFPA)

[12] NFPA 30, Flammable and Combustible Liquids Code.

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