Above Ground Storage Tanks: Design, Construction, Inspection and Maintenance

Above Ground Storage Tanks
Design, Construction, Inspection and Maintenance

‫بسم هللا الرحمن‬
‫الرحيم‬
SECTION 1
Introduction
Introduction
• World economic , and many
industries has built depending on it
as crude oil extortion or on it’s
products.
• For this reasons a lot of petroleum
equipments has designed and
improved to achieve the target of it .
• The tanks are one of this
equipments and can also be
considered of important one it
exists in different stages of
petroleum industry from crude
extortion in fields to refinery to
marketing .
Introduction
• For the important of the tanks many
of standard and design are issued for
tanks design and fabrication like:
1. API standard 620. design and construction of
large , weld ,low pressure storage tanks.
2. API 650. weld steel tanks for oil storage .
3. API 651. cathodic protection of above –ground
petroleum storage tanks .
4. API 652. lining of above –ground petroleum
storage tanks bottom.
5. API 653 . tank inspection , repair , alteration ,
and reconstruction .
Introduction
In this presentation we try to show some feature about :
• Tanks duties and importance .
• How we can choose the suitable type of tanks .
• Various types of tanks and it’s shapes .
• Tanks design considerations for it’s main components .
• Tanks clean out procedure for maintenance and repair
• Inspection of tanks .
• Tanks maintenance and repair
• Tanks tests after maintenance jobs
SECTION 2
TANKS TYPES AND SHAPES
There are many types and shapes which are used in petroleum
field , herein we will produce some of these types and shapes :
2: 1 Vertical tanks .
The vertical tanks are the widest applied
in petroleum field because it rather than
another types in design , construction and
maintenance jobs
Because it’s bottom , shell and roof are
nearly straight .
The vertical tanks are mainly consist of
bottom ,vertical shell and roof , this type
of tanks can be classified to following
mainly types depending on roof type:
2:1:1 Fixed Roof Tanks.

Fixed roof tanks are used for largest
storage capacity till 300000 bbl or more
and it can be sorted depending on internal
design pressure as follow :-
 Atmospheric tanks: a storage tank
which has been designed to operate at
pressure from atmospheric through 0.5
psig.
 Low pressure tank: a storage tank
designed to withstand an internal pressure
about 0.5 psig but not more than 1.5 psig .
 Pressure storage tank : a storage tank
designed to withstand an internal pressure
up to 10 lb. per . sq .in ( as radial cone
tanks )
2:1:1 Floating Roof Tanks.

A Floating roof on an oil-storage
tank has two principal functions: to
minimize evaporation loss, and to
reduce fire hazard.
When volatile liquid is stored in a
tank having a fixed roof some of it
is lost by evaporation. This loss is
made up of one or more of the
following parts
2:1:1 Floating Roof Tanks (Cont.)
(1) The loss caused by the breathing which accompanies

temperature changes.
(2) The loss resulting from the displacement of vapor by liquid
when the tank is filled.
(3) The loss occurring when any part of the liquid reaches the
boiling temperature.
Oil under the deck cannot ignite because air is excluded, and an explosive
mixture cannot form above the deck because it is not confined. Fire can
occur only in the space between the rim of the roof and the tank shell. This
space, however, is sealed with a fire-resistant material, and tests have
proved that a fire started there dies out quickly.
Types of Floating Roof Tanks:
Nearly all floating roofs in actual service fall within the following classifications:
(1) The Pan-type Floating Roof. consists of an essentially flat metal deck with a vertical
A roof floating directly on the oil eliminates the vapor space and prevents both breathing and filling
losses. In addition boiling losses from the more volatile products may be reduced by providing a
shading system to lower the temperature of the surface liquid, or by so constructing the roof that
vapor formed by boiling is trapped and retained until recondensed by cooler night temperatures.
Types of Floating Roof Tanks: (Cont.)
(1) The Pan-type Floating Roof. (Cont.)

A floating roof prevents fire by eliminating the conditions which might permit
the contents of a tank to burn at the periphery. The deck is coned slightly
downward towards the center and held in shape by radial trusses. A cross-section
of a tank containing a Wiggins Pan-type Roof is shown in Fig. 1. This roof will
safely sustain a load equivalent to 6 in. of water over the entire deck, but has the
disadvantage that a leak will cause it to sink. Pan-type roofs are effective in
preventing evaporation losses from products not sufficiently volatile to boil at the
highest temperature attained by the steel deck. However, the recent trend towards
the use of more volatile motor fuels has created a demand for more adequate
protection than these roofs afford
(2) The Double-deck Pontoon Roof:

• The roof shown in Fig. 2
consists of a pontoon divided by
bulkheads into compartments
which make it practically non-
sinkable.
• Should a leak develop in any
one compartment, the roof will
be kept afloat by the others.
• Breathing and filling losses are prevented by elimination of the vapor space, and
boiling losses are reduced by the shading which the upper deck provides
• Roofs of this type are frequently used for tanks having diameters of about 35 ft. or
less, but are seldom used for larger tanks because the cost of two complete decks is
prohibitive
(3) The Wiggins Pontoon Roof.:

• It illustrated in Fig. 3, has an
unstiffened center deck
attached to an annular
pontoon divided into
compartments by radial
bulkheads. The proportions
of the roof are such that it
will not tip or sink even
though the center deck is
filled with water to the top of
the pontoon.
(3) The Wiggins Pontoon Roof.: (Cont.)

• Leaks in the deck or in several of the pontoon compartments will not
submerge the roof because the remaining compartments have adequate
buoyancy keep it floating. The entire roof normally rests directly on the oil,
thus preventing breathing and filling losses, but when vapor is formed. by
boiling, the center deck flexes upward, trapping the vapor and retaining it
until recondensed by lower temperatures.
• In hot weather, several inches of water may be carried on the center deck
to prevent boiling if the tank contains an ‘unusually volatile product. Since
the buoyancy of this roof is ample to ensure freedom from operating
difficulties, and since the cost is commensurate with the evaporation
savings effected, it is more widely used than any other type of floating
roof.~
2:1:1 Combination of Fixed and Floating Roof
Some applications need special type of protection especially when there is
complete desire to prevent:
• Vapors losses duo to

high volatility from
light products
• The oxygen to
contact with the
liquid which can
affect badly by
oxygen
2:1:1 Combination of Fixed and Floating Roof : (Cont.)
For this reasons special tanks has designed with compound fixed and floating roof, this type of tanks
consist of normal vertical shell like the fixed roof type. In this type :
1- The fixed roof has designed to contain all normal attachments like vent open , breathing valve,
handrail , hatch tube open , manhole , and nitrogen blanket control valves.
2- Floating roof is moving inside tank shell and consist of A single roof
only and it has all attachments as in floating roof tanks like stairway, rim vapor sealing , support legs
, breathing , manhole.
2:1:1 Combination of Fixed and Floating Roof
Operation Theory :-
In this type floating roof operate as in floating roof tanks that the float move
up and down contacting liquid level through permitted height (other wise some
problem can be occur) and it’s seal system prevent the vapor leakage between
roof and shell periphery , then the space between fixed roof and floating roof is
filled with nitrogen through nitrogen blanket control valves to prevent any
oxygen to go inside the tank and the main target from this blanket are:-.
 reducing vapor losses

 to prevent oxygen contact which can lead to degradation for some
solvent medium like sulfolane
2:2 Horizontal Tanks:-
the horizontal tanks are one of tanks types that use in some cases in petroleum
field :
 to storage some light products which are produced in small quantities

 in fuel service stations
The using for this type has advantages and also disadvantage :
Advantages:
 it can put under or over ground and this can lead to use the area over the
tank without any serious.
 Putting it under ground is consider self insulation from ambient heat and
this can reduce vaporization
 It can fabricated as complete unit and transfer it to using site
The using for this type has advantages and also disadvantage :
Disadvantages:
This disadvantages are concerned by using it under ground because there

are some problems as:
 More corrosion can occur because the contact between tank body and
soil.
 The difficulty to perform the maintenance jobs which lead to ring it out
the ground .
Some technical assignments that are concerning the horizontal tanks :
The technical assignments for all types of horizontal tanks can summary as follow
:
1. it is fabricated from carbon steel plates as vertical tanks

2. it is designed on internal pressure at 0.35 kg/cm and tested by air at 0.7
kl/cm
3. some of it should be equipped with vacuum valves especially when it used
with volatile liquids .
4. it should be equipped with manhole open with diameter not less than 45 cm.
5. the tanks with small diameter and more length are better than big diameter
and short length because the first can reduce the suction head and the
foundation will be more safe .
2.3 -Spherical and spheroidal Tanks
For storage of very volatile oils

developing high vapor pressure,
tanks of spherical or spheroidal
forms are sometimes used. Such
tanks are better able, than tanks of
conventional form to resist
distortion as s. result of high
internal pressures. Stresses are
more uniformly distributed in such
tanks. If kept nearly full of oil, the
space available for accumulation of
vapor is comparatively small. Less
extensive foundations are required
than are necessary with
2.3 -Spherical and spheroidal
Tanks
Flat-bottomed tanks: an outside circular girder,
resting on concrete footings, supports the
weight of the tank and its contents. Internal
radial trusses assist in sustaining the
spherical form:
Tanks of these types are capable of withstanding
internal pressures a great as 100 lb. Per sq.
In. They are used primarily for storage of
natural gasoline’s or very high gravity
crude’s that develop high vapor pressures
2.4- Tanks Attachments:
The tanks attachments are the supplementary to the main tank components
( bottom- shell- roof ), this attachments are consider the tanks hand which by it can use the
tanks and by it can safe it also.
Herein we try to explore in appreviation the main tanks attachments and it’s Function:`
2.4.1 –Breathing and Vents:
the breathing valves or vents are used to protect the tanks

especially roofs from destroying because :
1. when the internal pressure increase over design pressure due to the increasing of
liquid column or from volatility vapor pressure.
2. when the internal pressure decreased due to unloading the tank rapidly.
The breather valves are fixed on tank fixed roof which are used with high volatile liquids .
The valve has two open ports as in drawings one for releasing the excess of internal pressure and
another permit to neutral the internal pressure by atmospheric air .
There is special type of breathing valve which permit to release the increasing of internal pressure
only and this type is used in tanks that the air is prevented to go inside the tank.
The breathing valves has advantage because it has self reset because it’s function depending on
disk weight . The vents are used for liquids has seldom or low volatility degree .
The vents are used for liquids has

seldom or low volatility degree .
2.4.2 –Cooling System:

All tanks and also tanks area should be
provided with suitable cooling system to be
used in emergency conditions by cooling
the tank shell from outside to decrease the
internal temperature and then internal
pressure .
The cooling system is consist of A net of
pipe lines 3”and 4” reach to tank top at the
middle of roof with special distributors to
distribute the cooling water over all the tank
or at the top of shell the cooling main line
connected to complete ring around shell top
, this ring provide with A lot special nozzles
to distribute the water over the tank body .
The cooling pipelines net should be ready to
use at any time and it’s control valves
should be locate in safe area to be handled
easy.
2.4.3 –Foam System:
All tanks especially are use to storage any

flammable liquids , it provided with A
foam system to damp any fire can be
occur in any tank inject the foam inside
the tank through special port at near
shell top to insulate the flammable liquid
from air ,this port is provided with
rupture disk to prevent the vapor go out at
normal condition .
The foam lines is prepared to connect to
discharge truck when a fire or connect to
complete system provided with foam tank
and this arrangement used for big number
of tanks in the same area .
2.4.4 –Seal:
Tanks sometimes become distorted due to foundation
settlement, and the diameter of the floating roof must
be made about 16 in. less than the tank, diameter to
prevent the roof from sticking. The space between the
roof rim and the tank shell must be provided with a
flexible seal, and the effectiveness of the roof in
preventing evaporation loss depends largely on the
tightness of this seal. Seals may be divided into two
general classes:
2.4.4 –Seal: (Cont.)

(1) The Deep Narrow Slot Seal: This seal may be defined one in which
the sealing element extends continuously from below the liquid surface
to a point 20 in. or more above it. The Wiggins Seal, which is of this
type, employs a series of steel shoes curved at top and bottom to permit
easy passage over rivet-heads and plate laps. These shoes are supported
and held against the tank shell by spring hangers attached to the roof.
Adjacent shoes are connected by vertical strips of flexible material called
the intershoe seals, and the tops of all shoes are connected to the roof by
a continuous strip of flexible seal called the continuous seal. This type of
seal is effective in preventing losses even when all of the shoes are held
away from the tank shell by the rivet-heads at a horizontal seam. Only a
small portion of the total surface area is exposed and the vapour which
forms in the narrow slot between—the shoes and the shell tends to form
a blanket preventing further evaporation. The flexible seal material
consists of an asbestos cloth base having an inert compound such as
Thiokol vulcanized into it on both sides. This provides a fire-resistant,
gas-tight seal which does not deteriorate under severe weather
conditions. The Wiggins Seal is illustrated in Figs.
2.4.4 –Seal: (Cont.)

(2) The Line Contact Seal. This seal is one in which the sealing
element contacts the shell along a horizontal line above the
liquid, surface. To be effective, the seal must make a continu6u~
and positive contact with the tank shell. Because a few small
openings will permit evaporation losses due to circulation of air
in the rim space, seals of this type have not been widely used on
roofs for riveted storage tanks. They are, however, suitable for
welded tanks having smooth interior surfaces. The double-deck
pontoon roof shown in Fig. 2 is equipped with a Haupt seal in,
which contact with the shell is maintained by a loop of flexible
material.
2.4.5 –Roof Supports:

A set of roof supports must be provided for
every floating roof, because tank connections
make it impractical to allow the roof to rest
directly on the bottom when the tank is empty.
The following types are suitable:
(I) Pipe Supports. Adjustable supports .consisting

of outer pipe sleeves welded to the roof and inner
pipes which bear on the tank-bottom may be used
with any type of roof. The two pipes are
connected by a pin, and it is standard practice to
provide two sets of holes, as shown that the roof
may be supported 3 ft. above the tank-bottom for
ordinary operation, or 6 ft. above the bottom for
cleaning. This type of support is advantageous
because the roof may be supported at either of
two different levels by using only one set of
supports.
2.4.5 –Roof Supports: (Cont.)
(2) Fixed Structural Supports.

Wiggins Pontoon Roofs are usually
supported in the low position on a
structural framework which will
safely sustain the roof and all the
water that can accumulate on the
deck. This framework, which is
illustrated in Fig. 3, aids materially in
the erection of the roof. Its
disadvantage is that some additional
means must be provided for
supporting the roof in a higher
position.
2.4.6 –Drainage System

Most tanks equipped with floating roofs do not have weather roofs over the top; therefore
it is necessary to provide a drain to remove rain-water from the deck. Several types have
proved satisfactory.
(1) Pipe Drains with Flexible Joints. A pipe
drain of the type shown in Fig. I may be used
with any floating roof. A check-valve is
provided at the inlet, and a gate-valve is
installed at the outlet. In the event of an
accident causing the drain to leak, the check-
valve in the sump may be closed to prevent
oil from flowing on to the deck. The gate-
valve at the outlet is normally kept closed, but
should be opened after every rain of any
consequence and during especially heavy
rains. A drain of this type is advantageous
because it removes water from the roof
without permitting it to come into contact
with the oil in the tank
(2) Short Pipe Drains. A double-deck

pontoon roof of the type shown in Fig.
2 may be equipped with a drain
consisting of a short pipe extending
through both decks. Rain-water falling
on the deck flows into the pipe and
down through the oil to the tank-
bottom where it can be removed
through the water draw-off. These
drains are free from operating
difficulties, but cannot be used in cases
where it is undesirable to have water
making contact with the tank contents.
Short pipe drains can be used only in
connection with roofs in which the
upper deck is everywhere above the
liquid surface
(3) Inverted Syphon Drains. The operation of the syphon
drains used with Wiggins Pontoon Roofs is based upon the fact
that water is heavier than oil. The roof in Fig. 3 is equipped
with one of these drains. A coupling is welded to the deck
and a pipe with a pan attached to the lower end is screwed
into the coupling from the underside of the deck. Another
piece of pipe with a cap on one end is screwed into the
coupling from the upper side of the deck. To put the drain into
operation it must be primed by removing the cap from this
plug pipe and pouring in enough water to fill the pan. Since
water is heavier than oil, the liquid-level in the pipe will be
below the deck and the plug pipe may be removed. Any water
on the deck will then flow into the drain, causing the water in
the pan to overflow and descend to the tank-bottom.
Although the pan has sufficient capacity to prevent the syphon
from becoming unprimed under normal conditions, the plug
pipe sh ould be left in place during long periods of dry weather
prevent the drain from versing due to loss of water by
evaporation.
2.4.7 –Ladders and Stairways
Some means must be provided for gaining access to the roof from the top of the
tank shell. The following types of ladders or stairways may be employed:
(1) Rolling Stairway. The stairway most frequently used is a ladder hinged at
the upper end and equipped at the lower end with wheels which roll on a
runway above the deck as the roof rises and falls. This type of stair, which
is illustrated in Fig. may be used on almost any roof, provided the height of the
tank is not greater than the diameter. The ladder is equipped with hand-rails at
the sides and is easy to ascend or descend except when the roof is at the bottom
of the tank.
(2) Ladder fixed to Roof. Floating roofs in shallow tanks may be equipped with
vertical ladders fastened at the lower end to the roof. The ladder extends above
the tank shell as the roof rises. Such ladders are not as easy to climb as ladders
of the rolling-stair type but are less expensive.
2.4.7 –Ladders and Stairways (Cont.)
(3) Pipe Ladder with Guide Sleeve. On tanks having a small diameter and a
great height, a fixed ladder made up of two vertical pieces of pipe with
horizontal rungs between is sometimes used. The ladder is connected to the top
of the tank shell and is held in place on the tank-bottom by means of a guide
which permits some radial movement. The ladder passes through an oval-
shaped guide sleeve in the roof.
(4) Chain Ladders. Various chain ladders have been devised and tried, but they
have not proved to be very successful. Such ladders are not only difficult to
ascend and descend but they frequently stick owing to the chain becoming
fouled.
2.4.8 –Guide Device:
A guiding device must be provided to prevent the floating roof from rotating in
the tank. This device may consist either of a roller guide with a flanged wheel
which runs on a vertical bar welded to the tank shell, or of a slotted guide shoe
of the type illustrated in Fig.
SECTION 3
Tank Selection
TANKS SELECTION
Tanks selection is very important

when are going to Build storage
tanks to store any petroleum
products.
Indeed the proper and economic
selection doesn’t Depend only on
special event or applied of A
formula but depend also on
complete studying for all ambient
circumstances which can affect in it .
Now we tray to show herein some of
considered factors that can lead to.
TANKS SELECTION
The proper selection of tanks types and this factors are :
 NUMBER OF TANKS
The number of tanks that can build is essential to defined
and this depend on:
•1. The total capacity that will be stored .

•2. The products type which can affect also in tank
shape and type.
TANKS SELECTION
STORING RATE .
In normal conditions the storing rate is depending on
1. Total production capacity , feature plans and season

changes
2. Transmitting types which can be by trucks ,
railway , sail tankers or pipe lines which is consider
the beast and the cheapest one .
TANKS SELECTION
Tank Type & Shape:

After all previous factors we can select tank diameter , height
and tank type , and herein we refer to that if there are more than
one tank of the same type, it will help to execute the required
maintenance as planed or when there some problem during
operation.
Butt we can say generally that the vertical tanks are the widest
type which are used in many applications especially in petroleum
field .
TANKS SELECTION
Tank Type & Shape:
When the vertical tanks type will be applied there are many factors are essential to be defined
until enable the designer to select the suitable type of vertical tanks and the famous of this factors
are :-
1. Petroleum Product Type : product specifications can effect in tank roof and internal pressure as follows:
A- product (1) this types distinguished with very high volatility , it’s flash point is less than 16° and it’s viscosity
about 27° or more. These products like crud oil , benzene and planes fuel , so the suitable types of vertical tank are :
- fixed roof with internal pressure .
- floating roof tank .
B- product (2) ,this types distinguished with high volatility butt less than the previous types and it’s flash point is
between 16°:64°like kerosene ,gasoline ,naphtha and turbine fuel so the suitable tank type to minimize the volatiles
vapors is floating roof and this may prevent any explosion can be occur by static – electricity or explosion mixture .
C) product(3) this types of products distinguished with low volatility and flash pint at 47°or more like diesel , solar
,asphalt and lub oil so the suitable tank types are fixed roof tank without internal pressure .
TANKS SELECTION
Tank Type & Shape:
2- Evaporation Losses
The evaporation losses are considering the dangerest problems which faced
tanks designer and users , because this there is some technique to reduce that
losses as follow :-
tanks with fixed roof with low internal pressure and external insulation
tanks with fixed roof with suitable internal pressure butt without external
insulation .
tanks with floating roof .
TANKS SELECTION
Tank Type & Shape:
3- Capital Cost
Storage tanks require
considerable capital investment ,
generally in which Case the
magnitude of the proposed is
controlled by the volume of the
fluid to stored , so the large
number of tanks are required
butt generally larger tanks give
A lower cost per unit volume
than smaller tanks as in fig.
TANKS SELECTION
Tank Type & Shape:
3- Capital Cost
However the large tanks are not always selected because of
the greater flexibility permitted in storing varity of fluids
and enable the user to perform the maintenance program ,
sometimes the d/ h ratio can effect in tank cost butt it
consider a function of the processing requirements and also
capital cost depend on the type of roof also on if there is
internal pressure or no.
TANKS SELECTION
Tank Type & Shape:
3- Capital Cost
Generally without referring to
land cost we can find that the
insulated fixed roof tanks with
low internal pressure has the
same cost versus to uninsulated
fixed roof tanks with internal
pressure to the same dimension .
Butt the tanks with floating roof
need for more cost because it
has many attachments especially
when is it consist of compound
type ( fixed and float ) as in fig.
SECTION 4
MATERIAL
MATERIAL
4.1 General
4.1.1 Materials used in the construction of tanks shall
conform to the latest edition of one of the specifications listed
in the following paragraphs, subject to the modifications and
limitations indicated in this standard. Material produced to
specifications other than those listed in Section 2 may be
employed, provided that the material is certified to meet all
the requirements of a material specification listed in this
standard and the material’s use is approved by the purchaser.
The manufacturer shall state in his proposal the material
specifications he intends to use.
MATERIAL
4.1 General (Cont.)

41.2 When any plate materials or tubular products on hand
cannot be completely identified by records satisfactory to the
purchaser as conforming to a specification listed in this
standard, the material or product may be used in the
construction of tanks covered by this standard only if the
material passes the tests prescribed in API650-Appendix N.
MATERIAL
4.2 PLATES
4.2.1 GENERAL
4.2.1.1 Except as otherwise provided for in 4.1, plates shall conform to the latest
edition of one of the specifications referred to in 4.2.2 through 4.2.5, subject to
the modifications and limitations indicated in this standard, including Figure 4-1.
4.2.1.2 Plate for shells, roofs, and bottoms may be on an edge-thickness basis or
on a weight(pound per square foot) basis, as specified in 4.2.1.2.1
through4.2.1.2.3.
4.2.1.2.1The edge thickness ordered shall not be n the computed design thickness
or the minimum thickness.
4.2.1.2.2 The weight ordered shall be great enough le an edge thickness not less
than the computed thickness or the minimum permitted thickness.
4.2.1.2.3 Whether an edge-thickness or a weight basis is used, an under run not
more than 0.01 inch from the computed design thickness or the minimum
permitted ‘s acceptable.
MATERIAL
4.2 PLATES
4.2.1 GENERAL (Cont.)
4.2.1.3 A1l lates shall be manufactured by the open – heath ,electric-

furnace, or basic oxygen process only. copper - bearing steel shall be used
if specified by the purchaser
4.2.1.4 Shell plates are limited to a maximum thickness of 1.75 inches

unless a lesser thickness is stated in this standard or in the plate
specification. Plates used as inserts or flanges may be thicker than 1.75
inches. Plates thicker than 1.5 inches shall be normalized or quench
tempered, killed, made to fine-grain practice, and impact tested.
MATERIAL
4.2.2 ASTM STANDARDS

The following standards can be obtained from the American Society for
Testing and Materials (ASTM), 1916 Race Street, Philadelphia,
Pennsylvania 19103:
A 36 - Structural Steel
Thickness less than or equal to 1.5 inches. None of the specifications for the
appurtenant materials listed in Table 1 of ASTM A 36 are deemed acceptable for tanks
constructed under this standard unless expressly stated in this standard.
A 131 - Structural Steel for Ships
Grade A, thickness less than or equal to 0.5 inch.
Grade B, thickness less than or equal to 1.0 inch.
Grade CS, thickness less than or equal to 1.5 inches (insert plates and flanges to 2
inches). Grade EH36, thickness less than or equal to 1.75 inches (insert plates and
flanges to 2 inches).
MATERIAL
4.2.2 ASTM STANDARDS: (Cont.)
A 283 - Low and Intermediate Tensile Strength Caron Steel Plates, Shapes, and Bars
Grade C, thickness less than or equal to 1.0 inch.
A 285 - Pressure Vessel Plates, Carbon Steel, Low and Intermediate Tensile
Strength Grade C, thickness less than or equal to 1.0 inch.
A 442 - Pressure Vessel Plates, Carbon Steel, Improved Transition Properties
Grades 55 and 60, thickness less than or equal to 1.5 inches.
A 516 - Pressure Vessel Plates, Carbon Steel, for Moderate- and Lower-
Temperature Service Grades 55, 60, 65, and 70, thickness less than or equal
to 1.5 inches (insert plates and flanges to 4 inches).
A 537 - Pressure. Vessel Plates, Heat-Treated, Carbon-Manganese-Silicon Steel
Class 1, thickness less than or equal to 1.75 inches (insert plates to 4 nches).
Class 2, thickness less than or equal to 1.75 inches (insert plates to 4 inches)
MATERIAL
4.2.2 ASTM STANDARDS: (Cont.)
A 633 - Normalized High-Strength, Low-Alloy Structural Steel Grades C and D,

thickness less than or equal to 1.75 inches (insert plates to 4 inches).
A 662 - Pressure Vessel Plates, Carbon-Manganese, for Moderate and Lower

Temperature Service Grades B and C, thickness less than or equal to 1.5 inches
A 678 - Quenched and Tempered Carbon Steel Plates for Structural Applications
Boron additions not permitted. Grade A, thickness less than or equal to 1.5 inches
(insert plates to 2.5 inches). Grade B, thickness less than or equal to 1.75 inches (insert
plates to 2.5 inches).
A 737 - Pressure Vessel Plates, High-Strength, Low-Alloy Steel

Grade B, thickness less than or equal to 1.5 inches.
MATERIAL
4.2.3 GENERAL REQUIREMENTS FOR DELIVERY
4.2.3.1 The material furnished shall conform to applicable requirements of the latest
edition of listed specifications but is not restricted with respect to locality of
manufacture.
4.2.3.2 This material is intended for fusion welding. Welding technique is of
fundamental importance, and welding procedures must provide welds whose strength
and toughness are consistent with the plate material being joined. All welding
performed for the repair surface defects shall be done with low-hydrogen welding
electrodes compatible in chemistry, strength, and quality with the plate material.
4.2.2.3 When specified by the plate purchaser, the steel shall be fully killed. When
specified by the plate ~ purchaser, fully killed steel shall be made to fine-grain j
practice.
MATERIAL
4.2.3 GENERAL REQUIREMENTS FOR DELIVERY (Cont.)
4.2.3.4 For plate made to specifications that

specify a maximum manganese content of
less than 1.60 percent . limit may be
Table (4-1) Max Permissible Alloy Content
increased to 1.60 percent(heat)at the option
of the plate producer to maintain the
required strength level, provided the
maximum carbon content is reduced to
0.20 percent (heat) and the weldability of
the plates is given consideration.
4.2.3.5 The use or presence of columbium,
vanadium, copper, nickel, chromium, or
molybdenum exceed the limitations of
Table 4-1 for the following materials: all
Group VI (see Table 4-2); CSA 1, Grade
350W; and 150 630, Grade Fe 52.
MATERIAL
4.2.4 HEAT TREATMENT OF PLATES
4.2.4.1 When specified by the plate purchaser, fully killed plates shall be heat treated to
produce grain refinement by either normalizing or heating uniformly for hot forming. If
the required treatment is to be obtained in conjunction with hot forming, the temperature
to which the plates are heated for hot forming shall be equivalent to and shall not
significantly exceed the normalizing temperature. If the treatment of the plates is not
specified to be done at the plate producer’s plant, the testing shall be carried out in
accordance with 4.2.4.2
4.2.4.2 When a plate purchaser elects to perform the required normalizing or fabricates by
hot forming (see4.2.4.1), the plates shall be accepted on the basis of mill tests made on
full-thickness specimens heat treated in accordance with the plate purchaser’s order. If the
heat treatment temperatures are not indicated on the purchase order, the specimens shall
be heat treated under conditions considered appropriate for grain refinement and for
meeting the test requirements. The plate producer shall inform the plate purchaser of the
procedure followed in treating the specimens at the steel mill.
4.2.4.3 On the purchase order, the plate purchaser shall indicate to the plate producer
whether the producer shall perform the heat treatment of the plates.
4.2.4.5 The tensile and impact tests, if any, shall be performed on each plate as heat
treated.
MATERIAL
4.2.5 IMPACT TESTING OF PLATES
4.2.5.1 When required by the purchaser or by 4.2.6 a set of Charpy V-notch impact
specimens shall be taken from plates after heat treatment, if any, and shall fulfill the stated
energy requirements. Test coupons shall be obtained adjacent to a tension test coupon.
Full-size impact specimens shall have their central axis as close to the plane of one-
quarter plate thickness as the plate thickness will permit.
4.2.5.2 When it is necessary to prepare test specimens from separate coupons, or when
plates are furnished by the plate manufacturer in a hot-rolled condition with subsequent
heat treatment by the fabricator, the procedure shall conform to ASTM A 20.
4.2.5.3 An impact test shall be performed on three specimens taken from a single test
coupon or test location. The average value of the specimens (with no more than one
specimen value being less than the specified minimum value) shall comply with the
specified minimum value, if more than one value is less than the specified minimum
value, or if one value is less than two-thirds the specified minimum value, three additional
specimens shall be tested, each of which must have a value greater than or equal to the
specified minimum value.
4.2.5.4 The test specimens shall be Charpy V-notch Type A (ASTM A 370), with the
notch perpendicular to the surface of the plate being tested.
MATERIAL
42.5.5. The testing apparatus, including the calibration of impact machines and the
permissible variations in the temperature of specimens, shall conform to ASTM A 370,
except that equivalent testing apparatus conforming to national or ISO standards is
acceptable.
MATERIAL
4.2.6- TOUGHNESS REQUIREMENTS
4.2.6.1 The thickness and design metal temperature of all shell plates, shell reinforcing
plates, shell insert plates, bottom plates welded to the shell, plates used for shell manhole
and nozzle necks, and plate-ring shell-nozzle flanges shall be in accordance with fig( 4.1)
.In addition, plates over 1.5 inches shall be steel made to fine-grain practice and heat
treated by normalizing, normalizing and tempering, or and tempering and shall be impact
tested according to 4.2.7.2’
4.2.6.2 Plates 1.5 inches and less in thickness, expect controlled-rolled plates (see
4.2.4.2), may be used or above the design metal temperatures indicated in Figure( 4-1)
without impact testing. For design metal temperatures lower than those minimums, the
material shall demonstrate adequate notch toughness in accordance with 4.2,7.1 unless
4.2.7.2 or 4.2.1 specified by the purchaser.
4.2.6.3 Plate used to reinforce shell openings shall be of the same material as the shell
plate to which it is attached, except that insert plates thicker than the shell plates shall be
of any appropriate material listed in Table 4-3 and Figure 4-1 but of equal or greater
strength and compatible with the adjacent shell material
4.2.6.4 The requirements of 4.2.6.3 apply only to shell nozzles and manholes. Materials
for roof nozzles and manholes do not require special toughness,
MATERIAL
MATERIAL
4.4 Piping and Forging
4.4.1 Except as otherwise specified in this standard, pipe and pipe couplings shall
conform to the latest edition of the following standards or to national standards
equivalent to the following:
API
Spec 5L Specification for Line Pipe Grades A, B, and X42
ASTM
A 53 Pipe, Steel, Black and Hot-Dipped, Zinc-Coated Welded and Seamless
Grades A and B
A 106 Seamless Carbon Steel Pipe for High-Temperature Service
Grades A and B
A 333 Seamless and Welded Steel Pipe for Low-Temperature Service
Grades I and 6
A 334 Seamless and Welded Carbon and Alloy-Steel Tubes for Low-Temperature Service
Grades 1 and 6
A 524 Seamless Carbon Steel Pipe for Atmospheric and Lower Temperatures
Grades I and II
A 671 Electric-Fusion- Welded Steel Pipe for Atmospheric and Lower Temperatures
MATERIAL
4.4 Piping and Forging
Except as otherwise specified in this standard, forgings shall conform to the latest
edition of the following standards or to national standards equivalent to the
following:
ASTM
A 105 Carbon Steel Forgings for Piping Components
A 181 Carbon Steel Forgings for General Purpose Piping
A 350 Carbon and Low-Alloy Steel Forgings Requiring Notch Toughness Testing
for Piping Components
Grades LF1 and LF2
MATERIAL
4.5 Flanges
4.5.1 Hub, slip-on, welding, and welding-neck flanges shall conform to the material
requirements for forged carbon steel flanges of ANSI B 16.5. Plate material used
for nozzle flanges shall have physical properties better than or equal to those required
by ANSI B 16.5. shell-nozzle flange materials shall conform to 4.2.6.1
4.5.2- For nominal pipe sizes over 24 inches, flanges that conform to API Standard 605
are an acceptable alternative, subject to the purchaser’s approval. Particular attention
should be given to ensuring that mating flanges of appurtenances are compatible.
4.6 Bolting
Bolting shall conform to the latest edition of ASTM A 36 or A 193. The purchaser
should specify on the order the desired shape of bolt heads and nuts and whether
regular or heavy dimensions are desired
SECTION 5
Tanks Design
DESIGN
5.1 DESIGN CONSIDERATIONS
5.1.1 Design Factors
The purchaser shall state the design metal temperature (based on ambient
temperatures), the design specific gravity, the corrosion allowance (if any), and the
design wind velocity.
5.1.2 External Loads
The purchaser shall state the magnitude and direction of external loads or restraint, if
any, for which the shell or shell connections must be designed. The design for such
loadings shall be a matter of agreement between the purchaser and the manufacturer.
5.1.3 Protective Measures
The purchaser should give special consideration to foundations, corrosion allowance,
hardness testing, and any other protective measures deemed necessary.
5.1.4 External Pressure
This standard does not contain provisions for the design of tanks subject to partial
internal vacuum; however, tanks that meet the minimum requirements of this standard
may be subjected to a partial vacuum of 0.15 kPa (I in. of water) of water pressure.
DESIGN
5.1 DESIGN CONSIDERATIONS
5.1.1 Design Factors
The purchaser shall state the design metal temperature (based on ambient
temperatures), the design specific gravity, the corrosion allowance (if any), and the
design wind velocity.
5.1.2 External Loads
The purchaser shall state the magnitude and direction of external loads or restraint, if
any, for which the shell or shell connections must be designed. The design for such
loadings shall be a matter of agreement between the purchaser and the manufacturer.
5.1.3 Protective Measures
The purchaser should give special consideration to foundations, corrosion allowance,
hardness testing, and any other protective measures deemed necessary.
5.1.4 External Pressure
This standard does not contain provisions for the design of tanks subject to partial
internal vacuum; however, tanks that meet the minimum requirements of this standard
may be subjected to a partial vacuum of 0.15 kPa (I in. of water) of water pressure.
DESIGN
5.1 DESIGN CONSIDERATIONS (Cont.)
5.1.5 Special Considerations
5.15.1 Foundation
The selection of the tank site and the design and construction of the foundation shall
be given careful consideration, as outlined in Appendix B, to ensure adequate tank
support The adequacy of the foundation is the responsibility of the purchaser.
5.15.2 Corrosion Allowances
When necessary, the purchaser, after giving consideration to the total effect of the
liquid stored, the vapor above the liquid, and the atmospheric environment, shall
specify the corrosion allowance to be provided for each shell course, for the bottom,
for the roof, for nozzles and manholes, and for structural members.
5.1.5.3 Service Conditions
When the service conditions might include the presence of hydrogen sulfide or other
conditions that could promote hydrogen-induced cracking, notably near the bottom of
the shell at the shell-to-bottom connections, care should be taken to ensure that the
materials of the tank and details of construction are adequate to resist hydrogen-
induced cracking. The purchaser should consider limits on the sulfur content of the
base and weld metals as well as appropriate quality control procedures in plate and
tank fabrication.
DESIGN
5.2 DESIGN CONDITIONS:
Code
Maximum Liquid Height
Service
Corrosion Allowance
Capacity (Net)
Live Load
Tank Diameter
Wind Velocity
Tank Height
Wind Pressure
Type of Roof
Seismic .Factor
Specific Gravity
Joint Efficiency
Design Pressure
Radiograph
Design Temperature
DESIGN
5.3 SHELL DESIGN :
5.3.1 General
5.3.1.1 The required shell thickness shall be the greater of the design shell
thickness, including any corrosion allowance, or the hydrostatic test shell
thickness, but the shell thickness shall not be less than the following:
5.3.1.3 The design shell thickness shall be computed on the basis that the tank is
filled to a level H (design liquid level) with a liquid that has a specific
gravity specified by the purchaser.
5.3.1.4 The hydrostatic test shell thickness shall be computed on the basis that the
tank is filled to a level H (design liquid level) with water.
5.3.1.5 The calculated stress for each shell course shall not be greater than the
stress permitted for the particular material used for the course. No shell
course shall be thinner than the course above it.
DESIGN
5.3 SHELL DESIGN : (Cont.)
5.3.2 Allowable Stress
5.3.2.1 The maximum allowable product design stress, Sd. shall be as shown in
Tables. The net plate thickness—the actual thickness less any corrosion
allowance—shall be used in the calculation. The design stress basis, Sd,
shall be either two-thirds the yield strength or two-fifths the tensile
strength, whichever is less.
5.3.2.2 The maximum allowable hydrostatic test stress, S,, shall be as shown in
Table (s 5t2). The gross plate thickness, including any corrosion allowance,
shall be used in the calculation. The hydrostatic test basis shall be either
three-fourths the yield strength or three-sevenths the tensile strength,
whichever is less.
DESIGN
5.3.3 Calculation of Thickness by the 1-Foot Method
5.3.3.1 The I-foot method calculates the thickness required at design points 03 m (I
ft) above the bottom of each shell course.
5.3.3.2 The required minimum thickness of shell plates shall be the greater of the
values computed by the following formulas:
In SI units:
td = 4.9D(H—0.3)G + CA
Sd
t t = 4.9D(H—03)
St
DESIGN
where
td = design shell thickness, in mm,
tt = hydrostatic test shell thickness, in mm,
D = nominal tank diameter, in m r of the top joined (that is, the shell plate or
the bottom
H = design liquid level, in .mm,
= height from the bottom of the course under consideration to the top
angle, if any; to the bottom of any overflow that of the shell including the top
limits the tank filling height; or to any other level specified by the purchaser,
restricted by an internal floating roof, or controlled to allow for seismic
wave action,
G = design specific gravity of the liquid to be stored, as specified by the

purchaser,
CA = corrosion allowance, in mm, as specified by the purchaser
Sd = allowable stress for the design condition, in MPa
St=allowable stress for the hydrostatic test condition, in MPa
DESIGN
5.4 BOTTOM PLATES
5.4.1 All bottom plates shall have a minimum

nominal thickness of 6 mm (1/4 in.) (70 kPa (102
lbf/in.2) 1, exclusive of any corrosion allowance
specified by the purchaser for the bottom plates.
Unless otherwise agreed to by the purchaser, all
rectangular and sketch plates (bottom plates on
which the shell rests that have one end
rectangular) shall have a minimum nominal width
of 1800mm (72 in.).
5.4.2 Bottom plates of sufficient size shall be
ordered so that, when trimmed, at least a 25mm (1
in.) width will project beyond the outside edge of
the weld attaching the bottom to the shell plate.
5.4.3 Bottom plates shall be welded in

accordance with lap-welded bottom joints or butt-
welded bottom joints .
DESIGN
5.4.4 ANNULAR BOTTOM PLATES
5.4.4.1 When the bottom shell course is

designed using the allowable stress for
materials in Group IV, IVA,V, or VI, butt-
welded annular bottom plates shall be used
(bottom annular –plate joint ). When the
bottom shell course is of a material in Group
IV, WA, V, or VI and the maximum product
stress (see 5.3.2.1) for the first shell course is
less than or equal to 160 MPa (23,200
lbf/in.2) or the maximum hydrostatic test
stress (see 5.3.2.2) for the first shell course is
less than or equal to 172 MPa (24,900 lb
f/in.2), lap-welded bottom plates (see lap-
welded bottom joints) may be used in lieu of
butt-welded annular bottom plates.
DESIGN

5.4.4.2 Annular bottom plates shall have a radial width that provides at least 600 mm (24 in.)
between the inside of the shell and any lap-welded joint in the remainder of the bottom and at least
a 50 mm (2 in.) projection outside the shell. A greater radial width of annular plate is required
when calculated as follows:
In Sl units:
215tb
(HG)0.5
where
tb = thickness of the annular plate in mm,
H = maximum design liquid level in m,
G = design specific gravity of the liquid to be stored.
DESIGN

5.4.4.3 The thickness of the annular bottom plates shall not be less than the thickness listed in
Table 5-3 plus any specified corrosion allowance.
DESIGN
5.5 Roof Design
 The most common shape for a tank roof is a cone although dome or umbrella roofs
are also used. In addition to these shape classifications, tank roofs may be classified
into two types, self-supporting and nonself-supporting.
 Regardless of shape or method of support, tank roofs are designed to carry a
minimum live load of 25 lb per sq ft in addition to the dead load. This live load is an
average figure which allows for combined wind and snow loads and for the weight
plant personnel who may travel across a roof to inspect the vessel or to reach a
manhole and so on.
 Self-supporting Conical Roofs. A self-supporting roof is one which is supported only
on its periphery without the aid of additional support from columns. Tank diameters
for self-supporting roofs generally do not exceed 60 ft and usually are less than 40
ft. Any greater spans require such heavy rafters that it is simpler to use one or more
supporting columns and thereby reduce the span. Such roofs usually consist of roof
plates supported on rafters.
DESIGN
5.5 Roof Design
 tanks with cone roofs the equation for stress m a cone under either an internal or
external pressure can derive as shown. The maximum stress will exist at the greatest
diameter of the con and will be:
fs = pd/21sinθ ---------------EQ( 1)
where : p=internal or external pressure pounds per square inch gage

d = diameter, inches
I = cone shell thickness, inches
θ= angle between cone element and horizontal
.
DESIGN
5.5 Roof Design

The stress as calculated by Eq.( 1 )will be controlling only in the case of thick cones
used with pressure vessels of limited diameter. In the case of large-diameter conical
roofs such as those used for storage tanks, the controlling factor is elastic
instability. The theoretical critical compressive stress that causes failure of a curved
plate given :
F critical= 0.6ET/R------EQ(2)
where E = modulus of elasticity of material, psi.

t= thickness
r = radius of curvature, inches (see Fig. 5.5.1)
f critical = theoretical critical stress at which failure
wrinkling occurs, pounds per square inch
DESIGN
5.5 Roof Design

The safe compressive stress that can be carried without wrinkling was investigated
by Wilson and Newanark (43) in a series of experimental tests. As a result of these
tests and others (44), it was found that the safe compressive stress that can be
imposed on a steel cylindrical shell with out failure by wrinkling is one twelfth. of
the theoretical critical stress and can be expressed for r as follows:
F allowable = 1.5(106 )t/r=1/3 yield point-----EQ(3)
This Equation can he modified for use with a conical roof
by referring to Fig. 5.5.1 and substituting for r as follows:

Fallow. = 1.5(1O6) t sin 0/6D-----EQ(4)
DESIGN
5.5 Roof Design

It is very important to recognize that the allowable compressive stress, Fallow is not
the conventional allowable stress for the material but is the safe stress that can be
applied without danger of failure by wrinkling. The compressive stress induced by live
and dead loads on the roof must not exceed the allowable compressive stress, f allow..
Eq (1). can be used to calculate the compressive stress induced by the roof loads, or
Eq.( 1). can he substituted into Eq(4) as follows:
sin 0 = (P/144)(12D) D / [ (2t sin 0) * 250,000t]
sin2 0=D2 /T2 (PX10/6)
sin0 = d/1000T -------Eq(5)
If live load = 25 lb per sq ft and dead load = 7.65 lb per sq ft (for 3/16 in. roof plates)
P = 32.65 lb per sq ft
If one substitutes for P in Eq. 5, min sin 0 =D/1000t =D/430t--------Eq(6)
Equation (6 )is the equation specified by API Standard 12 C for self-supporting
conical roofs
DESIGN
5.5 Roof Design

It is very important to recognize that the allowable compressive stress, Fallow is not
the conventional allowable stress for the material but is the safe stress that can be
applied without danger of failure by wrinkling. The compressive stress induced by live
and dead loads on the roof must not exceed the allowable compressive stress, f allow..
Eq (1). can be used to calculate the compressive stress induced by the roof loads, or
Eq.( 1). can he substituted into Eq(4) as follows:
sin 0 = (P/144)(12D) D / [ (2t sin 0) * 250,000t]
sin2 0=D2 /T2 (PX10/6)
sin0 = d/1000T -------Eq(5)
If live load = 25 lb per sq ft and dead load = 7.65 lb per sq ft (for 3/16 in. roof plates)
P = 32.65 lb per sq ft
If one substitutes for P in Eq. 5, min sin 0 =D/1000t =D/430t--------Eq(6)
Equation (6 )is the equation specified by API Standard 12 C for self-supporting
conical roofs
DESIGN
5.5.2 Conical Roofs with Structural

Support.
When the design calls for a conical roof with
structural Support,(fig 5.5.2.1)
slope, or pitch, of the roof of a 3/4-in. rise per 12
in. is recommended. The roof plates may be
ridged in order to decrease the number of
rafters required. Roof plates should not be
attached to the rafters. Roof plates of lap design
should have a minimum lap of 1 in. when tack
welded; moreover, if a continuous full-fillet weld
is used on all seams, it is necessary to weld only
the top side of the roof. For steel construction a
minimum thickness of 3/16 in. is recommended
for the roof plates. Figure (.5.2.1) is a
photograph showing assembly of structural
support for a tank roof before installation of
roof plates.
DESIGN
5.6- Tanks Welding Stander

(JOINTS)
5.6.1 Definitions
The definitions in 5.6.1.1 through 5.6.1.8 apply
to tank joint designs
5.6.1.1 double-welded butt Joint: A joint
between two abutting parts lying in
approximately the same plane that is welded
from both sides.
5.6.1.2 single-welded butt joint with backing:
A joint between two abutting parts lying in
approximately the same plane that is welded
from one side only with the use of a strip bar or
another suitable backing material.
5.6.1.3 double-welded lap Joint: A joint
between two overlapping members in which the
overlapped edges of both members are welded
with fillet welds.
DESIGN
5.6- Tanks Welding Stander (JOINTS)

5.6.1 Definitions (Cont.)
5.6.1.4 single-welded lap joint: A joint between two
overlapping members in which the overlapped edge of one
member is welded with a fillet weld.
5.6.1.5 butt-weld: A weld placed in a groove between
two abutting members. Grooves may be square, V-shaped
(single or double), or U-shaped (single or double), or they
maybe either single or double beveled.
5.6.1.6 fillet weld: A weld of approximately triangular
cross section that joins two surfaces at approximately right
angles, as in a lap joint, tee joint, or corner joint.
5.61.7 full-fillet weld: A fillet weld whose size is equal
to the thickness of the thinner joined member.
5.6.1.8 tack weld: A weld made to hold the parts of a
weld men in proper alignment until the final welds are
made.
DESIGN
5.6- Tanks Welding Standard (JOINTS)
5.6.2 Weld Size
5.6.2.1 The size of a groove weld shall be based on the joint penetration (that is. the depth of
chamfering plus the root penetration when specified).
56.3 Restrictions on Joints
6.3.1 Restrictions on the type and size of welded joints are given in 5.6.2.2 through 5.6.3.5.
5.6.3.2 Tack welds shall not be considered as having any strength value in the finished structure.
5.6.3.3 The minimum size of fillet welds shall be as follows:
On plates 5 mm 0/16 in.) thick, the weld shall be a full-fillet weld, and on plates more
than 5 mm 0/16 in.) thick, the weld thickness shall not be less than one-third the thickness
of the thinner plate at the joint and shall heat least 5mm (3/16 in.).
5.6.3.4 Single-welded lap joints are permissible only on bottom plates and roof plates.
5.6.3.5 Lap-welded joints, as tack-welded, shall be lapped at least five times the nominal
thickness of the thinner plate joined; however, with double-welded lap joints, the lap need
not exceed 50 mm (2 in.), and with single-welded lap joints, the lap need not exceed 25
mm (1 in.).
DESIGN
5.6- Tanks Welding Standard (JOINTS)
5.6.2 Weld Size
5.6.4 Welding Symbols
Welding symbols used on drawings shall be the symbols of the American Welding Society.
5.6.5 Typical Joints
5.6.5.1 General
Typical tank joints are shown in Figures( 5..6.5.1,2,3.) The wide faces of nonsymmetrical V-or U-butt joints
may be on the outside or the inside of the tank shell at the option of the manufacturer. The tank shell shall
be designed so that all courses are truly vertical.
5.6.5.2 Vertical Shell Joints
a. Vertical shell joints shall be butt joints with complete penetration and complete fusion attained by
double welding or other means that will obtain the same quality of deposited weld metal on the inside and
outside weld surfaces
b. Vertical joints in adjacent shell courses shall not be aligned but shall be offset from each other a
minimum distance of 5t. where t is the plate thickness of the thicker course at the point of offset.
5.6.5.3 Horizontal Shell Joints
a. Horizontal shell joints shall have complete penetration and complete fusion; however, as an alternative,
top angles may be attached to the shell by a double-welded lap joint.
b. Unless otherwise specified, abutting shell plates at horizontal joints shall have a common vertical
centerline.
SECTION 6
CLEANING PETROLEUM
STORAGE TANKS
Cleaning Petroleum Storage Tanks
6.1 Hazards of Tank Cleaning
1. Anyone engaged in the cleaning off tanks used to
store crude oil or unfinished products of petroleum
may suffer accidental injury as a result of:-
a. Explosion or fire
b. The presence of toxic liquids ,vapors, or dusts.
C An excess of petroleum vapors or a deficiency of
oxygen
d. Physical hazards such as slipping, failing. and
falling objects.
2. Fuel (in the vapor form) air (oxygen), and an ignition
temperature are necessary for combustion. No
combustion can occur without all three of these
essentials
6.1 Hazards of Tank Cleaning: (Cont):
3. Mixtures of petroleum vapor and air within certain limits can be ignited. The lower
and upper limits for these mixtures are approximately I per cent and 6 percent by
volume, respectively Other Vapors max’ have different combustible-gas or vapor
indicators are used to indicate the percentage the lower flammable Limit of vapors
present in the atmospheric.
4. Ignition does not occur in petroleum-vapor and air mixtures which are - richer than
the upper flammable limit Such mixtures may be ignited and burn at points of escape
from tanks at their hatches, manholes, or other openings. At these points air is present
in sufficient quantity’ to dilute the - rich vapors and produce a flammable mixture.
5. A tank may contain a ‘‘rich mixture after the oil has been removed. A mixture too
rich’ be ignition within a closed tank may quickly reach the flammable range alter the
tank has been opened, and when the mixture has been diluted with air.
6. Even after a tank has been freed of vapor, flammable mixtures again may be
formed by the admission of vapor or a liquid petroleum from some other source.
\vapors or liquid petroleum may enter the tank through unblanked lines or leaks
in the bottom of the tank. Vapors may evolve within the tank from sludge side-
wall scale, or residue; or from oil Trapped in hollow roof supports, foam
chambers, pontoons, or heating coils; or from oil-soaked wooden structures or
other absorbent materials.
7. Flammable mixtures may be ignited by open flames; or by sparks from electric

lamps, electric tools, electric fixtures, or appliances which are not explosion-
proof. or from worn or defective electric extension cords. In rare instances
mixtures may also be ignited by lightning and by sparks from the discharge of
static electricity which has accumulated on liquids of substantial depth and
extensive surface area.
8 Another source of ignition sometimes present in tanks used for the storage of sour
stocks iron-polysulfide deposits may form when sulfur or sulfur compounds in sour
stocks come in contact with the iron of storage tanks. Some of these iron polysulfides
may be of the pyrophoric type- under certain conditions when these pyrophoric-type
deposits come in contact with oxygen in air, a chemical reaction takes place which
Generates heat. If this heat is not dissipated, a temperature high enough to ignite a
flammable mixture may result.
9. Vapors which issue from openings in a tank shell may travel a considerable distance
from the tank, and any source of ignition may ignite such vapors.
10. Accident-prevention manual - should be consulted when tanks are to be cleaned
which at some time had contained leaded gasoline and then were used to store other
11. Hydrogen sulfide(h2s), is ,a very toxic gas may be found in significant concentration
in and around tanks used in sour -stork service, such as crude oil, gas oil. ‘
12. Poor health, colds, overheating’ fatigue. Or lowered physical resistant from
any cause accentuates the effects of any toxic hazards which maybe present
13. If petroleum vapor in strong concentration is breathed, a reaction results

which produces a stage of excitement leading to unconsciousness similar to
that produced by alcohol or chloroform- Although with rest and fresh air :here
may be recovery in a few hour., all physical reactions which result from such
vapor inhalation should promptly be reported to a physician If breathing has
stopped, artificial respiration should be applied promptly by a competent
person. Prior to medical attention.
14. atmospheric (air) within a tank which registers on the vapor indicator more
than 14to20 percent of the lower explosive limit is considerable unsafe for
breathing.
15. in addition- to injury which might result from tires or explosions, from toxic
conditions, or from asphyxiation anon, injury may result from other causes, such as:
a. Failure to use personal protective equipment
b. A discharge of steam or petroleum product into a tank.
c. Dropping of swing line.
d Objects which have been dropped or which fall from the upper part of a tank.
e Falling from scaffolding, stairways, or Ladders.
J. Falling from or through the roof of a tank.
g Tripping over hose lines or over other objects
h. Slipping on tank floors.
i Colliding with structural tank supports or piping.
j Structural failure of a tank
k. Insufficient light.
6.2 Cleaning Methods & Procedures:
16. The previously discussed hazards which are encountered in the cleaning of
tanks which contained crude oil or unfinished petroleum products can be
controlled by proper planning, inspection, and training
17. Tank-cleaning operation involve various major steps, as follow
a. Preliminary preparations including external inspection of the tank and a
survey of the immediate area; training and indoctrination of the crew, and
inspection of equipment.
b. Controlling sources of ignition.
c. Emptying the tank by pumping and floating, blanking-off tank after all the oil
possible has been removed
d. Vapor-freeing the tank
c. Testing the tank for hydrocarbon vapor and toxic gas
f. Opening tank, and removal and disposal of sludge.
18. The supervisor who is competent to handle tank-cleaning operations should
determine the type of crude oil or unfinished petroleum product which the tank
previously contained, as well as the indicated amount of sludge within the tank
and the physical condition of the tank itself. A survey of the surrounding area
should be made to determine whether it is safe to perform the cleaning
operations.
19. Equipment used for tank cleaning operations should be inspected to assure that
it is free of defects, and that it is adequate for the purpose intended
20. Personal protective equipment—including boots. gloves, breathing apparatus,
and canister masks should be inspected to assure that it is of first quality and in
perfect condition
21. All sources of ignition should be eliminated from the area where flammable
vapors may be present ..This area should be kept free of all sources of ignition
from the time tank cleaning starts until the tank is gas free and the sludge has
been removed. Signs should be posted warning that sources of ignition should be
kept out of the area—
6.2 Cleaning Methods &
Procedures:
22. Only work essential to vapor removal
should be performed before the tank has
been vapor-freed and before sludge has
been removed.
23 . Before the tank is opened ,all the oil

should be pumped or drained off to the
lowest possible level through the lowest
tank connection .
24. This pumping or draining may be
augmented by the addition of water
through existing piping connections-not
through a tank opening .
25- Blanking off is accomplished by first
closing all the valves nearest the tank ,
then breaking the connection ,and
placing blinds in all the lines
26. Mechanical ventilation effected by an adequate air supply furnished by an air mover
of the eductor type, or by a mechanical blower or fan, or by some similar device, is a
quick and safe method to vapor—free tank It is preferable to exhaust vapors through
the roof manhole
27. Ordinary. (natural) ventilation may be used to remove tank vapors. All roof and shell
manhole covers should be removed—in that order-—---so that air will circulate freely
through the tank. Caution should be exercised when bottom manhole covers are
removed because of escaping petroleum vapors. Natural ventilation can be augmented
by the use of wind sails.
28. Steam may be used to heat the contents of a tank and thereby assist in natural
ventilation, if steam is used, it should he introduced through some connection in or
near the bottom of the tank. To avoid any possibility of excessive pressure or vacuum,
it is essential that there be an opening in the roof during steaming and until the tank
has cooled. After the tank has been heated with steam to the highest practicable
temperature, steam should be shut off, and all remaining roof and shell manhole
covers should be removed. Because of the chimney effect, the tank is ventilated as air
enters the shell openings and vapor-air mixtures leave through the roof openings.
29- If steam is used in an attempt to avoid the present of flammable mixture , steam
should be supplied at rate sufficiently high to heat tank atmosphere to a temperature
of at least 170F to dissipate vapor effectively ,otherwise it will condense .
30. Steam which enters a tank ma’, generate static electricity .The steam hose nozzle and
its piping should be bond properly to control charges left on the nozzle
31. Steam, for cleaning side walls, should be used after the tank atmosphere is below the
lower explosive limits
32. Special attention should be given to the vapor-freeing of tanks which previously
contained sour stocks because of the possible presence of pyophoric deposits the
reaction of these deposits with oxygen generates heat; And, if this heat is not
dissipated, the ignition temperature of flammable mixtures may be reached. This
source of ignition can be controlled by isolating these deposits from air, or by
dissipating the heat to prevent a temperature rise-
33. Tanks which have been in sour-stock service, and which have been blanketed with
inert gas or hydrocarbon vapors, present a different vapor-freeing problem. One
recommended procedure for vapor-freeing and removal of pyrophoric deposits from
shell and roof surfaces involves the following steps:
a. First steam the tank until the interior surfaces are wet with condensate.
b. Then install high-capacity air movers in the roof manholes, and large fog
nozzles in the neck of the shell manholes .
c. Without delay, turn on the fog nozzles, and immediately there after turn on the air
movers.
(The interior surfaces of that tank will be kept wet, and the ingoing air will be
thoroughly humidified
34. Tanks must be tested to determine the amount of hydrocarbon vapors present, and for
the presence of hydrogen sulfide in’ tanks which contained sour stocks
36. Tests for hydrocarbon vapor are made with a vapor- indicator. Anyone who makes
such tests should be thoroughly instructed in the handling and reading of vapor
indicators, and he should satisfy himself chat the instruments used are in proper
working condition. Tests should be made at various points within the tank.
If ventilating equipment is in operation, samples should be taken which arc
representative of the tank atmosphere.
37. frits tests or the atmosphere should be made at openings where vapors are leaving the
tank When the vapor indicator registers not more than 14 to 2Opercent of the lower
explosive limit, the tester should then enter the tank and make further tests. Tests for
vapor should be repeated at frequent intervals and, if the indicator shows the
presence of vapors above this limit everyone in the tank should leave promptly. No
one should reenter until the atmosphere within the tank is again at or below this limit,
unless he is wearing protective respiratory equipment which provides an independent
air supply.
38. If the tank has contained leaded gasoline at any time after a previous thorough
cleaning, reference should be made to Par. 10 of this manual

40 The presence of hydrogen sulfide can be detected by the way this gas blackens
moistened lead-accreted paper. Also, hydrogen-sulfide detectors are available to
test an atmosphere for this gas. Anyone who uses these instruments should be
thoroughly instructed in the handling and reading of them.
Before men are permitted to enter, the tanks should be inspected for loose rafters,
loose angle and loose columns, and to assure that swing so. :ton lines have been
lowered to the floor.
41. While men are cleaning the tank, they should be under the constant
observation of a competent man outside the tank ,should be available for
rescue of those within the tank in the event of an emergency. It is
recommended that someone be available who is qualified to administer
artificial respiration and simple first aid. Anyone who has been exposed to
hydrocarbon vapors or toxic gases should have immediate medical attention
42. Paint used on the inside or outside surfaces of the tank should be assumed to
have a high lead content. An approved lead-fume respirator, or other
protective respiratory equipment suitable for this purpose, should be worn
because intense hear, such as burning or cutting ( on these surfaces, may
result in a significant and addition hazard from lead fumes).
6.3 PERSONAL PROTECTION
43- Boots and gloves are required items for the
protection of the workmen who clean tanks.
44- First quality boots made of a martial
resistant to water and oil
45- Gloves made of material impervious to oil
46. Whenever hydrogen sulfide is present
outside a tank, canister-type masks,
equipped with a canister approved for use
in atmospheres which contain organic
vapors and acid gases (yellow canisters),
should be worn. Hydrogen sulfide may be
present at tank openings or near material
which has been removed from a rank which
contained sour stock. In no case should a
canister-type mask be worn by any one
who enters a tank.
46 A canister-type mask should be securely fitted and tested before anyone enters a
hazardous area, and it should not be removed except in a safe atmosphere.
47 Connections on the hose of the blower-type mask should be’ inspected frequently, an I
kept tight at all times. If the hose is pulled or twisted, a connection may be loosened
while: the hose is in use. Therefore, men should be instructed not to step over their own
hose lines.
48 Under no circumstances should the man who operates the blower leave the job unless he
is replaced. An uninterrupted air supply to the masks must be maintained until all
persons are out of the tank and have removed their face pieces.
49 The user of the mask may remove his hat or cap to enable him to secure a tight fit of the
face piece. It is essential that such articles as tobacco and chewing gum be removed from
the mouth. After the face piece has been adjusted and tightened, it should be tested for
leaks. This is accomplished by closing the end of the tube with the palm of the hand; or
by pinching the tube, and inhaling. If the face piece collapses against the face, the fit is
satisfactory. If it does not, leaks should be located and eliminated.
50. Protective eye equipment should
be worn during
the scraping of scale, cutting of
rivers, or Spreading of sawdust or
other absorbent Such equipment
should be cleaned frequently, and
should be washed and sterilized
up on the completion of each job.
51. Some petroleum stocks irritate
the skin, and excessive exposure
may cause serious discomfort and
injury. Skin which has been in
contact with these
50. Protective eye equipment should
be worn during
the scraping of scale, cutting of
rivers, or Spreading of sawdust or
other absorbent Such equipment
should be cleaned frequently, and
should be washed and sterilized
up on the completion of each job.
51. Some petroleum stocks irritate
the skin, and excessive exposure
may cause serious discomfort and
injury. Skin which has been in
contact with these
SECTION 7
Inspection
Inspection
7.1 General
Periodic in-service inspection of tanks shall he performed by an Authorized Inspector as defined
herein (sec 4. 10) unless otherwise noted.
7.2. Inspection Frequency Considerations
7.2.1 Several factors must be considered to determine inspection intervals for storage tanks. These
include (but are not limited to) the following:
a. The nature of the product stored. b.The results of visual maintenance checks.
c. Corrosion allowances and corrosion rates. d. Corrosion prevention systems.
e. Conditions at previous inspections.
f. The methods and materials of construction and repair.
g. The location of tanks, such as those in isolated or high risk areas.
h. The potential risk of air or water pollution.
i. Leak detection systems.
j. Change in operating mode (for example: frequency of fill cycling, frequent grounding of floating
roof support legs).
k. Jurisdictional requirements.
Inspection
72.2 The interval between inspections of a tank (both internal and external)
should be determined by its service history unless special reasons indicate
that an earlier inspection must be made. A history of the service of a given
tank or a tank in similar service (preferably at the same site) should be
available so that complete inspections can be scheduled with a frequency
commensurate with the corrosion rate of the tank. On-stream, nondestructive
methods of inspection shall be considered when establishing inspection
frequencies.
7.2.3Jurisdictional regulations, in some cases, control the frequency and interval

of the inspections. These regulations may include vapor loss requirements.
seal condition. leakage. proper diking. and repair procedures. Knowledge of
such regulations is necessary to insure compliance with scheduling and
inspection requirements
Inspection
7.3 External Inspection

7.3.1 routine in-service inspections
7.3.1.1 The external condition of the tank shall be monitored by close visual
inspection from the ground on a routine basis . this inspection may be
done by owner / operator personal . and can be done by other than
inspectors
7.3.1.2 The interval of such inspections shall be consistent with conditions at the
particular site, but shall not exceed one month.
7.3.1.3 This routine in-service inspection shall include a visual inspection of the
tank’s exterior surface checking for: leaks; shell distortions; signs of
settlement; corrosion; and condition of the foundation, paint coatings,
insulation systems and appurtenances.
Inspection
7.3.2 SCHEDULED INSPECTIONS

7.3.2.1 All tanks shall be given a formal visual external inspection by an inspector
qualified in accordance with 4. 10. at least every 5 years or at the quarter
corrosion-rate life of the shell, whichever is less. Tanks may be in
operation during this inspection. ;
7.3.2.2 Insulated tanks need to have insulation removed only to the extent
necessary to determine the condition of the exterior wall of the tank or the
roof.
7.3.2.3 Where exterior tank bottom corrosion is controlled by a cathodic
protection system. periodic surveys of the system shall be conducted in
accordance with API RP 651.
7.3.2.4 Tank grounding system components such as shunts or mechanical
connections of cables shall be visually checked. Recommended practices
dealing with the prevention of hydrocarbon ignition are covered by API
RP 2003.
Inspection
7.4 Internal Inspection

7.4.1 GENERAL :
Internal inspection is primarily required to:
a. Ensure that the bottom is not severely corroded and leaking.
b. Gather the data necessary for the minimum bottom and shell thickness
assessments. As applicable, these data shall also take into account
external ultrasonic thickness measurements made during in-service
inspections
c. Identify and evaluate any tank bottom settlement.

Inspection
7.4.2 Inspection Intervals
7.4.2.1 Intervals between internal inspections shall be determined by the
corrosion rates measured during previous inspections or anticipated
based on experience with tanks in similar service. Normally. bottom
corrosion rates will control and the inspection interval will be governed
by the measured or anticipated corrosion rates and the calculations for
minimum required thickness of tank bottoms. The actual inspection
interval shall be set to ensure that the bottom plate minimum thickness
at the next inspection are not less than the values listed in Table7-I. In
no case. however, shall the internal inspection interval exceed 20 years
4.4.2.2 When corrosion rates are not known and similar service experience is
not available to determine the bottom plate minimum thickness at the
next inspection, the actual bottom thickness shall be determined by
inspection(s) within the next 10 years of tank operation to establish
corrosion rates
Inspection
7.4.3 ALTERNATIVE INTERNAL INSPECTION INTERVAL
For unique combinations of service, environment and construction, the
owner/operator may establish the internal inspection interval using an
alternative procedure. This alternative procedure shall include method
for determining bottom plate thickness, consideration of environmental
risk, consideration of quality of inspection and analysis of corrosion
measurements. This alternative procedure shall be documented and
made part of the permanent record of the tank.
7.5 Alternative to Internal Inspection to Determine Bottom Thickness

In cases where construction, size or other aspects allow external
access to the tank bottom to determine bottom thickness, an external
inspection in lieu of an internal inspection is allowed to meet the data
requirements of Table 4-I. However, in these cases, consideration of
other maintenance items may dictate internal inspection intervals. This
alternative approach shall be documented and made part of the
permanent record of the tank.
Inspection
7.6 Preparatory Work for Internal Inspection
Specific work procedures shall be prepared and followed when

conducting inspections that will assure personnel safety and health and
prevent property damage in the workplace .
7.7 Inspection Checklists
The enclosure (tables c-1and C/2 ) provides sample checklists of items

for consideration when conducting in-service and out-of-service
inspections .
Inspection
7.8 Records
7,8.1 GENERAL
Inspection records form the basis of a scheduled
inspection/maintenance program. (It is recognized that records may not
exist for older tanks and judgeruents must be based on experience
with tanks in similar services.) The owner/operator shall maintain a
complete record file consisting of three types of records, namely:
construction records, inspection history. and repair! alteration history.
7.8.2 CONSTRUCTION RECORDS

Construction records may include nameplate information, drawings,
specifications, construction completion report and any results of
material tests and analyses.
Inspection
7.8 Records: (Cont.)
7.8.3 INSPECTION HISTORY

The inspection history includes all measurements taken, the condition of
all parts inspected, and a record of all examinations and tests. A complete
description of any unusual conditions with recommendations for
correction or details which caused the conditions shall also be included.
This file will also contain corrosion rate and inspection interval
calculations.
7.8.4 REPAIR/ALTERATION HISTORY
The repair/alteration history includes all data accumulated on a tank from
the time of its construction with regard to repairs, alterations,
replacements, and service changes (recorded with service conditions such
as stored product temperature and pressure). These records should
include the results of any experiences with coatings and linings.
Inspection
7.9 Reports
4.9.1 Reports recommending repairs shall

include reasons for the repairs, and
sketches showing location and
extent.
7.9.2 General inspection reports shall

include metal thickness
measurements, conditions found,
repairs, any settlement
measurements, and
recommendations
Inspection
7.10 Inspector Qualifications:
7.10.1 Qualified inspectors shall have education and experience equal to at least
one of the following:
a. A degree in engineering plus 1 year of experience in inspection of

tanks, pressure vessels or piping.
b. A 2-year certificate in engineering or technology from a technical
college, and 2 years of experience in construction, repair, operation or
inspection, of which one year must be in inspection of tanks, pressure
vessels or piping.
c. The equivalent of a high school education, and 3 years of experience in
construction, repair, operation or inspection, of which one year must be
in inspection of tanks, pressure vessels or piping.
d. Five years of experience in the inspection of above-ground storage
tanks in the petroleum or chemical industries.
Inspection
7.10 Inspector Qualifications: (Cont.)
7.10.2 An owner/operator of tanks may designate tank inspectors qualified in
accordance with 7.10. 1. Such inspectors shall have the necessary
authority and organizational freedom to perform their duties.
Authorized Inspectors shall be certified by an agency as provided in
this standard, in accordance with Appendix D. This requirement will
become effective eighteen (18) months after the date of issuance of the
requirement.
7.10.3 Qualification requirements for personnel performing nondestructive

examinations( Ultrasonic examination of shell for lamination shall be
made in the immediate area affected when :
1. adding a reinforcing plate to an existing unreinforced penetration .
2. add a hot tap connection.
Inspection
CHECKLISTS FOR TANK INSPECTION:
Tables C-I and C-2 are sample checklists illustrating tank components
and auxiliary items that should be The checklist considered for internal
and external inspection of tanks. This information is provided as
guidance to the owner/ operator for developing an inspection
assessment schedule for any specific tank installation. format facilitates
the recording of inspection findings.
SECTION 8
Tank Maintenance and
Repair
Tank Maintenance & Repair
8.1 General
8.1.1 The basis for maintenance and repairs shall be an API Standard 650
equivalence should be done for tanks due to the problems that occurred during
operation .
8.1.2 This problems can represented in:
• Internal/external corrosion
• Leaks
• Mechanical damage to some tank parts
8.13 Problems effects
• Economic losses
• Pollution of ground water
• hazard
8.2
8.2.1- Corrosion.:
External factors
corrosive atmospheric condition:
sulfurous or acidic atmospheric
(protective coating-paint-cathodic protection)
leaks: cracks and pits:
(repair by welding patches or replacement)
soil corrosion: (under ground water):
(sand injection, concrete pumping, bottom (replacement))
Electrolytic corrosion: (galvanic cell):
Inside shell ,under bottom ,soil corrosion, clay electrolytic properties
repair by cathodic protection
tank leak under bottom:
improper sealed foundation:
Internal factors:
Tank content: ( corrosive chemical)
Acidic salts, clorides, hydrogen sulfide, water
(Lining with high resistance materials
Roof internal corrosion:
(Hydrogen sulfide vapors ,water vapor ,oxygen)
Electrolytic corrosion: (galvanic cell)
(Cathodic protection)
Hydrogen blistering: ‘(stress corrosion cracking) -
Caustic embrittlement: (cracks. Flows)
Internal factors:
Tank content: ( corrosive chemical)
Acidic salts, clorides, hydrogen sulfide, water
(Lining with high resistance materials
Roof internal corrosion:
(Hydrogen sulfide vapors ,water vapor ,oxygen)
Electrolytic corrosion: (galvanic cell)
(Cathodic protection)
Hydrogen blistering: ‘(stress corrosion cracking) -
Caustic embrittlement: (cracks. Flows)
8.2.2 leaks
Cracks and mechanical deterioration
a-REASONS:
 flange leaks.  concentrated welding.
 weld cracks.  insufficient reinforcement.
 tank plate cracks.  stresses caused by settlement of earth.
 faulty welding.  vibration (mixers).
 earth quake.  poor design or repair.
 unrelieved stress
C- Crack repair
- Sand blasting ,grinding/ gauging , filling by welds
- Temporary blockers: air harening adhesive fillers application to steel plates.
- Drilling of pits ,tapping ,fixing of tapered plug.
- Roof leaks: soft patches of rubber asbestos ,neoprene ,and glass cloth with
asphalt
- Permanent repair: welding of steel plate patches to cracked area and dye
penentrant test application.
- Corrosive soil / bottom settlement repaired by pumping sand, concrete
injection ,bottom replacement.
8.3- Removal and Replacement of Shell

Plate Material
8.3.1- minimum thickness of replacement shell plate
thickness of the replacement shell plate shall not be
less than the greatest nominal thickness of any plate
in the same course adjoining the replacement plate
except where the adjoining plate is a thickened
insert plate. Any changes from the original design
conditions, such as specific gravity, design pressure,
liquid level, and shell height, shall be considered.
8.3.2 minimum dimensions of replacement shell plate
8.3.2.1 _ The minimum dimension for a replacement
shell plate is 12 inches or 12 times the thickness of
the replacement plate, whichever is greater. The
replacement plate may be circular, oblong, square
with rounded corners or rectangular with rounded
corners except when an entire shell plate is
replaced.. Refer to Figure 8-I for typical details of
acceptable replacement shell plates.
8.3- Removal and Replacement of Shell Plate Material
8.3.3 weld joint design
8.3.3.1 Shell replacement plates shall be welded with “ butt joints with complete penetration and
complete fusion.
8.3.3.2-Weld joint design for replacement shell plates shall be in accordance to API Standard 65%
Joints in lap-welded shell tanks may be repaired according to the original standard of
construction however, lapped patch plates are not permitted .butt repair is acceptable by
removing and replacement.
8.3.3.3 For existing shell plates over 1/2 inch thick, the outer edge of the butt weld attaching the
replacement shell plate shall be at least the greater of 8 times the weld thickness or 10 inches
from the outer edge of any existing butt-welded shell joints. For existing shell plates 1/2 inch
thick and less, the spacing may be reduced to 6 inches from the outer edge of vertical joints or
3 inches from the outer edge of horizontal joints. See Figure 8-1 for minimum dimensions.
For existing shell plates over 1/2 inch thick, the outer edge of the butt weld attaching the
replacement shell plate shall be at least the greater of 8 times the weld size or 10 inches from
the edge (toe) of the fillet weld attaching the bottom shell course to the bottom except when
the replacement shell plate extends to and intersects the bottom-to-shell joint at approximately
90 degrees. For existing shell plates 1/2 inch thick and less, this spacing may be reduced to 6
inches. The edge of any vertical weld joint attaching a replacement plate shall be at least 12
inches from the edge of a weld joint in the annular plate ring or sketch plate. See Figure
8.4 Repair of Shell Penetrations
8.4.1 Repairs to existing shell

penetrations shall be in
compliance with API Standard
650.
8.4.2 Reinforcing plates may be added
to existing unreinforced nozzles
when deemed appropriate. The
reinforcing plate shall meet all
dimensional and weld spacing
requirements of API Standard
650. See Figures 8-2 and 8-3 for
acceptable details.
8.4 Repair of Shell Penetrations
8.4.1 Repairs to existing shell

penetrations shall be in
compliance with API Standard
650.
8.4.2 Reinforcing plates may be added
to existing unreinforced nozzles
when deemed appropriate. The
reinforcing plate shall meet all
dimensional and weld spacing
requirements of API Standard
650. See Figures 8-2 and 8-3 for
acceptable details.
8.5 Repair of Tank Bottoms

8.5.1- Repairing a portion of tank bottoms
8.5.1.1The critical zone for repairs to tank bottoms is within the annular plate
ring, within 12 inches of the shell, or within 12 inches of the inside edge of
the annular plate ring No welding, welded-on patch plates or weld overlays
~are permitted within the critical zone except for welding of: widely
scattered pits cracks in the bottom plates, the shell-to-bottom weld, or
where the bottom or annular plate is being replaced.
8.5.1.2 If more extensive repairs are required within the critical zone than those
listed in 8.5.1.1, the bottom plate under the bottom ‘shell course shall be cut
out and a new plate shall be installed. Weld spacing requirements shall be
in accordance with 3.1.5.4 and 3.1.5.5 of API Standard 650.
8.5.1.3 The repair of sumps located within the critical zone shall be in
accordance with 8.5. 1 .2.
8.5.2 Replacement of Entire Tank Bottom

8.5.2.1Requirements governing the installation of a replacement bottom over an existing
bottom are given in 8,.5.2.1.1 through 8.5.2.1.5
8.5.2.1.1 A suitable non-corrosive material cushion such as sand, gravel, or concrete, 3 to 4
inches thick, shall be used between the old bottom and the new bottom.
8.5.2.1.2 The shell shall be “slotted” with a uniform cut made parallel to the tank bottom.
The cut edges in the slot shall be ground to remove all slag and burrs from the
cutting operation. The new bottom plate shall be extended outside the shell as
required by API Standard 650. All rules for weld spacing shall be followed.
8.5.2.1.3 Voids in the foundation below the old bottom shall be filled with sand, crushed
limestone, grout, or concrete
8.5.2.1.4 -For floating roof tanks, the new bottom profile must keep the roof level when it is
resting on its support legs in the down position. The support legs can be either
jacked up to maintain the original height or shortened by the same amount as the
thickness of the cushion and new bottom plate .fg(8.4)
8.5.2.1.5 New bearing plates for floating roof support legs and for fixed roof support
columns shall be installed.
8.5.2 Replacement of Entire Tank Bottom

8.6 Repair of Fixed Roofs

8.6.1 supported cone roofs
8.6.1.1--The minimum thickness of new roof plates shall be 3/16 inch plus any
corrosion allowance as specified in the repair specifications. In the event roof
live loads in excess of 25 pounds per square foot are specified (such as
insulation, operating vacuum, high snow loads), the plate thickness shall be
based on analysis using the allowable stresses per 3.10.3 of API Standard 650
8.6.1.2 The roof supports (rafters, girders, columns, and bases) shall be repaired
or altered such that under design conditions the resulting stresses do not
exceed the stress levels given in 3. 10.3 of API Standard 650.
8.6.2 Self-supported Roofs
8.6.2.1 The nominal thickness of new roof plate shall be ¾6 inch or the required
plate thickness given in 3. 10.5 or 3.10.6 of API Standard 650, plus any
specified corrosion allowance, whichever is greater.
8.6.2.2 The details of the roof-to-shell junction shall meet the requirements of 3.
10.5 or 3. 10.6 or Appendix F of API Standard 650, as applicable, for the
intended service. Frangible joint design, or the need for emergency venting
devices in accordance with API Standard 2000, shall meet the requirements of
3. 10.2.5 of API Standard 650.
8.7- Floating Roofs

8.7.1 external floating roofs
Any method of repair is acceptable that will restore the roof to a condition
enabling it to perform as required
8.7.2 internal floating roofs
Repairs to internal floating roofs shall be made in accordance with the original
construction drawings. if available. If the original construction drawings are
nor available, the roof repairs shall be in compliance with the requirements
Appendix.
8.7.3 repair of leaks in pontoons
All leaks in pontoons or compartments of double deck floating roofs shall be
repaired by rewelding the leaking joints and/or the use of patch plates.
8.8 Repair or Replacement of Floating Roof Perimeter Seals

8.8.1 PRIMARY SEALS
Rim-mounted primary shoe seals and toroidal seal systems can be removed, repaired, or
replaced~ lb minimize evaporation losses and reduce potential hazard to the workers, no more
than one—fourth of the roof seal system should be out of an in-service tank at one time.
Temporary spacers to keep the roof centered shall be used during the repairs. Primary seal
systems mounted partly or fully below the bolting bar or top of the rim usually cannot be reached
to allow removal in service. In this case, in-service repairs are limited to replacement of the
primary seal fabric
8.8.2 secondary seals
Rim-mounted and shoe-mounted secondary seals may be readily installed, repaired, or replaced
while the tank is in service.
8.8.3—seal—shell gap
Repair and other corrective actions to maintain seal-to-shell gap requirements, includes:
a. Adjusting the hanger system on primary shoe seals, and adding foam filler in toroidal seals.
b. Increasing the length of rim mounted secondary seals in the problem area.
c. Replacing all or part of the primary seal system along with possible installation of a rim extension
for a secondary seal. This step shall be taken only after checking the annular space variation at
several levels from low pump out to high liquid level.
SECTION 9
EXAMINATION AND
TESTING
SECTION 9 :EXAMINATION AND TESTING
9.1 Nondestructive Examinations

9.1.1 GENERAL
9.1.1.1 Nondestructive examination procedures, qualification and
acceptance criteria shall be prepared for visual, magnetic particle,
liquid penetrate, ultrasonic, and radiographic methods in accordance
with API Standard 650 and the supplemental requirements given
herein.
9.1.1.2 Personnel performing nondestructive examinations shall be

qualified in accordance with API Standard 650 and the supplemental
requirements given herein
9.2 welding defects :

 Slag inclusion fig (9.1)
 Porosity fig (9.1)

 Cracks fig(9.2)
 Over lap and under fill fig(9.3)
Under cut


9.3- METHODS OF INSPECTING JOINT
9.3.1 Radiographic Method

For the purposes of this paragraph, plates shall be considered of the same
thickness when the difference in their specified or design thickness does not
exceed 1 / 8 inch.
APPLICATION
Radiographic inspection is required for shell butt welds annular-plate butt
welds and flush-type connections with butt welds. Inspection by radiographic
methods is not required for roof-plate or bottom-plate welds or for welds
joining roof plates to the top angle, the top angle to the shell plate, shell plates
to bottom plates, or appurtenances to the tank.

9.3.1.1.1 The following requirements apply to vertical joints:

a. For butt-welded joints in which the thinner shell plate is less than or equal to
3/8 inch thick, one spot radiograph shall be taken in the first 10 feet of completed
vertical joint of each type and thickness welded by each welder or welding
operator. The spot radiographs taken in the vertical joints of the lowest course
may be used to meet the requirements of Note 3 in Figure 6-1 for individual
joints. Thereafter, without regard to the number of welders or welding operators,
one additional spot radiograph shall be taken in each additional 100 feet
(approximately) and any remaining major fraction of vertical joint of the same
type and thickness. At least 25 percent of the selected spots shall be at junctions
of vertical and horizontal joints, with a minimum of two such intersections per
tank. In addition to the foregoing requirements, one random spot radiograph shall
be taken in each vertical joint in the lowest course (see the top panel of Figure
9.3-1).
9.3.1.1.1 The following requirements apply to vertical joints:

b. For butt-welded joints in which the thinner shell plate is greater than 3/8 inch
but less than or equal to 1 inch in thickness, spot radiographs shall be taken
according to Item a. In addition, all junctions of vertical and horizontal joints in
plates in this thickness range shall be radiographed; each film shall clearly show
not less than 2 inches of weld length on each side of the vertical intersection. In
the lowest course, two spot radiographs shall be taken in each vertical joint: one
of the radiographs shall be as close to the bottom as is practicable, and the other
shall be taken at random (see the center panel of Figure 9.3-1).
c. Vertical joints in which the shell plates are greater than 1 inch thick shall be
fully radiographed. All junctions of vertical and horizontal joints in this thickness
range shall be radiographed; each film shall clearly show not less than 2 inches of
weld length on each side of the vertical intersection (see the bottom panel of
Figure 9.3-1).
d. The butt weld around the periphery of an insert manhole or nozzle shall be
completely radiographed
9.3.1.1.2 The following requirements apply to horizontal joints:
One spot radiograph shall be taken in the first 10 feet of completed horizontal butt
joint of the same type and thickness (based on the thickness of the thinner plate at
the joint) without regard to the number of welders or welding operators.
Thereafter, one radiograph shall be taken in each additional 200 feet
(approximately) and any remaining major fraction of horizontal joint of the same
type and thickness. These radiographs are in addition to the radiographs of
junctions of vertical joints required by Item c of 6.1.2.2 (see Figure 9.3-1).
9.3.1.1.3 An equal number of spot radiographs shall be taken from the work of
each welder or welding operator in proportion to the length of joints welded.
9.3.1.1.4 When bottom annular plates are required to radiograph, the radial joints
shall be radiographed as follows: (a) For double butt-welded joints, one spot
radiograph shall be taken on 10 percent of the radial joints; (b) For single-side
welded joints using a backup bar, one spot radiograph shall be taken on 50
percent of the radial joints. Locations of radiographs shall preferably be at the
outer edge where the shell-plate joint joins the annular plate. The minimum length
of each radiograph shall be 6 inches..
9.3.1.2 - Magnetic Particle Examination
When magnetic particle examination is specified, the method of examination shall

be in accordance with Section V, Article 7, of the ASME Cod
Magnetic particle examination shall be performed in accordance with a written
procedure that is certified by the manufacturer to be in compliance with the
applicable requirements of Section V of the ASME Code.
9.3.1.3- Ultrasonic Examination
9.3.1.3.1 When ultrasonic examination is specified, the method of examination

shall be in accordance with Section V, Article 5, of the ASME Code.
9.3.1.3.2 Ultrasonic examination shall be performed in accordance with a written

procedure that is certified by the manufacturer to be in compliance with the
applicable requirements of Section V of the ASME Code.
9.3.14- Liquid Penetrate Examination
9.3.1.4.1 When liquid penetrant examination is specified, the method of

examination shall be in accordance with Section V, Article 6, of the ASME
Code.
9.3.1.4.2 Liquid penetrant examination shall be performed in accordance with a

written procedure that is certified by the manufacturer to be in compliance with
the applicable requirements of Section V of the ASME Code.
9.3.1.5- Visual Examination

9.3.1.5.1 A weld shall be acceptable by visual inspection if the inspection shows
the following:
a. The weld has no crater cracks or other surface cracks.
b. Undercutting does not exceed the limits(maximums acceptable under cutting is
1/64 inch for vertical butt joints, for horizontal butt joints undercutting not
exceeding 1/32 in chin depth) for vertical and horizontal butt joints. For welds
that attach nozzles, manholes, cleanout openings, and permanent attachments,
undercutting shall not exceed 1/64 inch.
c. The frequency of surface porosity in the weld does not exceed one cluster (one
or more pores) in any 4 inches of length, and the diameter of each cluster does not
exceed 3/32 inch.
d. Rewelding is required if the resulting thickness is less than the minimum
required for design hydrostatic test .
9.3.1.6 VACUUM TESTING
9.3.1.6.1 Vacuum testing is conveniently
performed using a metal testing box 6 inches
wide by 30 inches long with a glass window
in the top. The open bottom is sealed against
the tank surface by a sponge-rubber gasket.
Suitable connections, valves, and gauges
should be provided.
9.3.1.6.2 Approximately 30 inches of the
seam under test is brushed with a soap
solution or linseed oil. In freezing weather, a
nonfreezing solution may be necessary. The
vacuum box is placed over the coated section
of the seam, and a vacuum is applied to the
box. The presence of porosity in the seam is
indicated by bubbles or foam produced by air
sucked through the welded seam.
9.4- INSPECTION OF TANK BOTTOM WELDS

Upon completion of welding of the tank bottom, the welds shall be inspected by
one of the following methods:
a. Air pressure or vacuum shall be applied to the joints, and a soap film, linseed
oil, or another material suitable for the detection of leaks shall be used to detect
any leaks.
b. After at least the lowest shell course has been attached to the bottom, water (to
be supplied by the purchaser) shall be pumped underneath the bottom. A head of 6
inches of liquid shall be maintained using a temporary dam to hold that depth
around the edge of the bottom. The line containing water for testing may be
installed temporarily by running it through a manhole to one or more temporary
flange connections in the bottom of the tank, or the line may be installed
permanently in the sugarede beneath the tank. The method of installation should
be governed by the nature of the sugarede. Reasonable care shall be taken to
preserve the prepared sugarede under the tank.
9.5- INSPECTION OF REINFORCEMENT-PLATE WELDS
After fabrication is completed but before the tank is filled with test water, the
reinforcement plates shall be tested by applying up to 15 pounds per square inch
gauge pneumatic pressure between the tank shell and the reinforcement plate on
each opening using the telltale hole
9.6- TESTING OF THE SHELL
After the entire tank is completed but before any permanent external piping is
connected to the tank, the shell (except for the shell of tanks designed in
accordance with Appendix F) shall be tested by one of the following methods:
a. If water is available for testing the shell, the tank shall be filled with water as
follows: (1) to the maximum design liquid level, H; (2) for a tank with a tight
roof, to 2 inches above the weld connecting the roof plate or compression bar to
the top angle or shell; or (3) to a level lower than that specified in Subitem 1 or 2
when restricted by overflows, an internal floating roof, or other freeboard by
agreement between the purchaser and the manufacturer. The tank shall be
inspected frequently during the filling operation, and any welded joints above the
test-water level shall be examined in accordance with Item b.
9.6- TESTING OF THE SHELL

b. If sufficient water to fill the tank is not available, the tank may be tested by (1)
painting all of the joints on the inside with a highly penetrating oil, such as
automobile spring oil, and carefully examining the outside of the joints for
leakage; (2) applying vacuum to either side of the joints or applying internal air
pressure as specified for the roof test in 5.3.7 and carefully examining the joints
for leakage; or (3) using any combination of the methods stipulated in Subitems 1
and 2.
9.7- TESTING OF THE ROOF
9.7.1 Upon completion, the roof of a tank designed to be gastight shall be tested
by one of the following methods:
a. Applying internal air pressure not exceeding the weight of the roof plates and
applying to the weld joints a soap solution or other material suitable for the
detection of leaks.
b. Vacuum testing the weld joints in accordance with 9.3.1.6 to detect any leaks.
9.8 Repair of Defective Welds

Types of weld flaws and nonconformance that need repair are described in 9.8.1
through 9.8.2
9.8.1Cracks, lack of fusion and reject able slag and porosity that need repair shall
be removed completely by gouging and/or grinding and the resulting cavity
properly prepared for welding.
9.8.2 Generally, it is not necessary to remove existing weld reinforcement in

excess of that allowed by API Standard 650 when discovered on an existing tank
with a satisfactory service history. However,
9.8 Repair of Defective Welds

Types of weld flaws and nonconformance that need repair are described in 9.8.1 through
9.8.2
9.8.1 Cracks, lack of fusion and reject able slag and porosity that need repair shall be
removed completely by gouging and/or grinding and the resulting cavity properly prepared
for welding.
9.8.2 Generally, it is not necessary to remove existing weld reinforcement in excess of that
allowed by API Standard 650 when discovered on an existing tank with a satisfactory
service history. However,
9.8.3. Existing weld undercut deemed unacceptable based upon suitability for service
considerations shall be repaired by additional weld metal, or grinding, as appropriate.
9.8.4 Welded joints that have experienced loss of metal due to corrosion may be repaired
by welding.
9.8.5 Arc strikes discovered in or adjacent to welded joints shall be repaired by grinding
and/or welding. Arc strikes repaired by welding shall be ground flush with the plate.
9.9 ROUNDNESS
Radii measured at 1 foot above the bottom corner weld shall not exceed the following
tolerances:
Diameter Radius Tolerance
(feet) (inches)
<40 ±1/2
4Oto <150 ±3/4
150to<250 ±1
. >250 ±1 1/4
9.10 - PEAKING : With a horizontal sweep board36 inches long peaking shall not exceed
1/2 inch.
9.11 BANDING : With a vertical sweep board 36 inches long, banding shall not exceed
½ inch.
SECTION 10
Case Studies
SECTION 10 Case Studies
10-1 -Floating roof deviation and reset

10.1.1 tank descriptions:
type : compound floating and fixed roof
service : sulfolane charge tank
diameter : 18 m
design height : 15 m
max operation height : 12.75 m
floating roof type : bulk head
floating roof weight: 12482 kg
10.2 the case : sinking of the

floating roof under liquid
10.2.1 the procedure which had taken
to save the tank:
•unloading the tank and remove
all internal liquid
•isolate all tank connection
•ventilating the tank from H.C
gases
•opening all tank nozzles to
refresh the internal air
10.3- The expected reasons :

a- Liquid overflow the roof at the opposite direction of
hatchet pipe may cause roof unbalance which caused
settling to floating roof.
b- The roof hanged to hatchet pipe due to complete contact
between hatchet pipe and roller guide which caused
friction force which caused settling the opposite roof side
during roof fall down .
c- High suction rate from tank may cause floating roof
unbalance and this cause the roof to hinge with hatchet
pipe and this lead to settle the roof from the opposite side
.
10.5 THE REPAIR

a- the inspection had performed for all tank parts and structure .
b- reviewing the mechanical properties for rafter- shell connections bolts
(especially sheer stress due to roof weight )
c- preparing 5 over head crane with load capacity 5 ton
d- hinged the over head cranes in fixed roof rafters in distributed
locations ,and fixed its chains in the floating roof .
e- lifting the floating roof starting from the lower point until it became
leveled then down the roof to the lowest position(maintenance
position)
f- change and repair all defaulted parts ( seal, supports legs ,,roof
contents ) by new ones .fg5
g- all required tests had been performed.
Thank You …..

Above Ground Storage Tanks: Design, Construction, Inspection and Maintenance

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Above Ground Storage Tanks: Design, Construction, Inspection and Maintenance

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Above Ground Storage Tanks

Design, Construction, Inspection and Maintenance

2:1:1 Fixed Roof Tanks.

2:1:1 Floating Roof Tanks.

2:1:1 Floating Roof Tanks (Cont.)

(1) The loss caused by the breathing which accompanies

(1) The Pan-type Floating Roof. (Cont.)

(2) The Double-deck Pontoon Roof:

(3) The Wiggins Pontoon Roof.:

(3) The Wiggins Pontoon Roof.: (Cont.)

• Vapors losses duo to

 reducing vapor losses

 to storage some light products which are produced in small quantities

This disadvantages are concerned by using it under ground because there

1. it is fabricated from carbon steel plates as vertical tanks

For storage of very volatile oils

2.4.1 –Breathing and Vents:

the breathing valves or vents are used to protect the tanks

2.4.1 –Breathing and Vents:

The vents are used for liquids has

2.4.2 –Cooling System:

2.4.3 –Foam System:

All tanks especially are use to storage any

2.4.4 –Seal: (Cont.)

2.4.4 –Seal: (Cont.)

2.4.5 –Roof Supports:

(I) Pipe Supports. Adjustable supports .consisting

2.4.5 –Roof Supports: (Cont.)

(2) Fixed Structural Supports.

2.4.6 –Drainage System

2.4.6 –Drainage System

(2) Short Pipe Drains. A double-deck

Tanks selection is very important

The proper selection of tanks types and this factors are :

•1. The total capacity that will be stored .

The proper selection of tanks types and this factors are :

1. Total production capacity , feature plans and season

The proper selection of tanks types and this factors are :

Tank Type & Shape:

The proper selection of tanks types and this factors are :

Tank Type & Shape:

The proper selection of tanks types and this factors are :

Tank Type & Shape:

4.1 General (Cont.)

4.2.1.3 A1l lates shall be manufactured by the open – heath ,electric-

4.2.1.4 Shell plates are limited to a maximum thickness of 1.75 inches

4.2.2 ASTM STANDARDS

4.2.2 ASTM STANDARDS: (Cont.)

4.2.2 ASTM STANDARDS: (Cont.)

A 633 - Normalized High-Strength, Low-Alloy Structural Steel Grades C and D,

A 662 - Pressure Vessel Plates, Carbon-Manganese, for Moderate and Lower

A 737 - Pressure Vessel Plates, High-Strength, Low-Alloy Steel

4.2.3 GENERAL REQUIREMENTS FOR DELIVERY (Cont.)

4.2.3.4 For plate made to specifications that

5.3.3 Calculation of Thickness by the 1-Foot Method

G = design specific gravity of the liquid to be stored, as specified by the

5.4.1 All bottom plates shall have a minimum

5.4.3 Bottom plates shall be welded in

5.4.4 ANNULAR BOTTOM PLATES

5.4.4.1 When the bottom shell course is

5.4.4 ANNULAR BOTTOM PLATES

5.4.4 ANNULAR BOTTOM PLATES

5.5 Roof Design