Oil Storage Tank Construction Procedure

(Reference codes and specifications as per API STD 650)

Above Ground Oil Storage tank construction methodology can be performed in

the sequence listed below:

1. Construction of Foundations
2. Identification of Tank Materials
3. Storage Tank Construction and Fabrication
3.1 Annular and Bottom Plates Fabrication
3.2 Shell Plates Fabrication
3.3 Tank Roof Fabrication
3.4 Nozzle and Shell Attachments Fabrication
3.5 Stair Way and Hand Railing
4. Storage Tank Erection
4.1 Annular Plates Laying
4.2 Bottom Plates Laying
4.3 Shell Course Erection
4.4 Erection of Roof Structures and Roof Plates
4.5 Tank Appurtenances and Shell Attachments Installation

1. Construction of Foundations
Earth Foundations with Concrete Ringwall

Foundation will be able to carry the shell load directly, so that a concrete
ringwall foundation should be used. It provides better distribution of the
concentrated load of the shell to produce uniform soil loading under the tank.

Concrete ringwall provides a level, solid starting plane for construction of the
shell and preserving its contour during construction. It prevents tank bottom
material erosion and minimizes moisture under the tank.

Foundation design consideration

 Subsurface Investigation and construction

 Tank Grades(surface)
2. Identification of Tank Materials
These all Items required for tank fabrication like plates, fittings and other
components of the tankage system must be clearly identified by marking heat
numbers by hand-punching on each part. Each weld joint shall be marked with a
joint number with welder number.

3. Storage Tank Construction and Fabrication

All fabrication works like tank material identification, marking, cutting, rolling
and welding work must be performed as mentioned in latest API 650. It must be
meet all safety, Quality control and Non Destructive Testing requirements.

Lay all the plates, structural items and pipes in such a fashion that facilitates
proper checking of dimension and heat number. Mark the components as per the
Approved drawings.

3.1 Tank Annular and Bottom Plates Fabrication

 Mark the plates as per drawing.

 Perform the cutting operation after proper inspection.
 All the cutting operation shall be performed by Gas cutting method.
 Grind the cut edges smoothly to get rid of burrs and slag.
 Stack the plates at designated places in proper sequence.
 The packing strip shall be fitted and tacked with an annular plate.
 After completion of the fabrication underside of annular and bottom plates
shall be sand blast and cleaned after painted as per specification.
 Check the joint position, Root gap, for welding. After welding do the
inspection by weld visual examination and NDT as per API 650.

3.2 Tank Shell Plates Fabrication

 Mark the plates as per drawing.

 Perform the cutting operation after proper inspection.
 All the cutting operation includes bevelling shall be performed by Gas
cutting method on all four sides.
 Grind the cut edges smoothly to get rid of burrs and slag.
  The prepared plates shall be shifted by crane to the rolling area.
 The plates shall be fed to the rolling machine by means of a crane and
proper lifting tools and tackles.
 The plate shall be rolled as per drawing details and therefore the radius shall
be checked using Template.
 Proper care shall be taken for the plate curvature. The template used to
check rolling curvature accurately.
 The Rolled plates shall be inspected and acceptance within 3mm of
tolerance limit.
 The rolled plates shall be shifted to the sand blasting yard to hold out the
sand blast as per specification.
 Final profile and dimensions check shall be permit before sent for erection.

3.3 Tank Roof Fabrication

 Mark the plates as per drawing.

 Structural items of the roof shall be fabricated as per drawing.
 Perform the cutting operation after proper inspection.
 Grind the cut edges smoothly to get rid of burrs.
 Roof structure fasteners shall be arranged as per drawing.

3.4 Appurtenances and Shell Attachments Fabrication

 Mark the specified attachments as per drawing.

 All the cutting operations shall be performed by gas cutting or Machine
cutting method.
 Grind the cut edges smoothly to get rid of burrs.
 The whole shell nozzle, flanges and other requirements shall be fabricated
as per approved drawing.
 All the fabrication and welding activities shall be performed after the stage
wise inspection wherever required.
 NDT requirement as per API 650 specification.
3.5 Stairway and Hand railing of storage tank

 All the structural items shall be straightened before marking and cutting.
 Mark the components as per drawing.
 All the cutting operation shall be performed by Gas cutting method.
 Grind the cut edges smoothly to get rid of burrs and slag.
 Fabrication like welding, drilling, fitting work shall be performed as per
drawing and after the clearance from the inspection authority.
 After the fabrication of these structural items shall be blasted and painted as
per requirement.

4. Storage Tank Erection

There are two methods for storage tank erection

 The conventional method

 The Jacking method

The conventional Method

 In the conventional methods, Crane used for tank erection as a shell by shell
method.
 At first the Annular and bottom plates are erected.
 Then the lower course shell is erected and finally the upper course shell is
erected.
 When complete the full shell course erection after erect the Roof structure
and plates.
 Then erect the stairs and handrails.
 Finally all shell attachments and appurtenances installed as pre drawing.
 The conventional method is tough and unsafe as compared to the jacking
method.
The Jacking Method

 The Jacking method is the advanced form of tank erection.

 A number of hydraulic Jacks to be used directly subjected to the weight of
the tank to be lifted.
 A system of hydraulic pressure hoses interconnects the hydraulic jacks
which are energised by the action of a hydraulic pump.
 We calculate the overall weight of the tank ages except for the bottom and
first shell course accordingly jacks are used.
 Jacking method is just opposite of the conventional method, the
construction sequence is first upper shell course erected and finally lower
shell course is erected.

The Jacking Procedure

The below steps are while followed erecting tanks by jacking method.

 Tank pad to be checked and tolerances to be verified.

 Standard practice is to keep a 3000mm distance between two jacks.
However the number of hydraulic jacks can be increased to meet additional
wind load.
 Since jacks are to be mounted on the Annular plates these need to be
placed.
 Annular plate joints are to be aligned and welded.
 After that erect the top two shell courses. Align properly and welded. All the
works on these two courses including the erection of the Curb angle, Wind
girder, Roof structure and Hand railing etc to be completed.
 Next place the hydraulic jacks along the circumference of a circle drawn
about 100mm from the shell plate circle. The maximum arc distance
between the two jacks shall not exceed 3000mm.
 Jacks are available 8T/12T/18T capacities. So arrange the hydraulic jacks of
predetermined quantities before the erection. Anchor the jack supporting
columns to the base plates.
 When the subassembly consisting of top two courses, roof structure/roof,
wind girder and railing etc.
  Is lifted, erect the shell plates of the third shell course from the top, after
lifting the entire subassembly to the require height.
 Align the vertical joints and weld. Next the subassembly is lowered is
complete the alignment and welding of the girth seam.
 The hydraulic jacks can be released and lowered after the alignment of the
girth seam.
 In similar way to erect the other shell courses fill all courses are erected.
 Finally, align the shell to the bottom joint and check for the verticality of the
completed tank. Weld the shell to the bottom joint.
 Now all other balance works like fixing and welding of shell manholes,
nozzles etc can be completed.
 Power pack machine is used to lift the jack. The pump the oil to jack through
the hose pipes to lift the jack.
 Stay pipe, also known as supporting pipes. These pipes provide support to
jack and trestle pipes. Basically these pipes are supporting the vertical
trestles to maintain verticality.
 Trestle pipe is the vertical members in the jacking system that carries loads
of jacks. While installing this assembly we need to take extra care of these
vertical members. So that verticality of the tank is maintained.
 Jack move over the trestles by teeth. These get support from base plates in
the tank bottom.

4.1 Laying of storage Tank Annular Plate

 Getting clearance for Annular plate laying Check the foundation as per
specification latest API 650.
 Mark the 0 degree, 90 degree, 180 degree, 270 degrees. This coordinates
guiding for the point of reference.
 Lay the Annular plates as per the approved drawing. Out radius of the
annular plate shall be on the positive side (5 to 10mm), so as to realize
the ultimately required radius after weld shrinkage.
 The orientation of the annular plate joint shall be as per the approved
drawing.
 Fit-up the annular plate joints shall be using proper fixtures.
  Take care while fit-up, such these should not any gap between the
annular plate and packing strip.
 Annular plate joints welding shall be performed by welding alternative
joints at four quadrants (parts).
 Qualified welders shall be engaged for the welding work consistent with
WPS.
 Complete the welding, clean the ultimate weld surface by wire brushing
and grinding.
 Remove the fixtures which were used for fit-up of the annular joint and
grind the tack welds.
 Radiography shall be taken as per API 650.

4.2 Laying of storage Tank Bottom Plate

 Lay the middle plate on the inspiration top as per drawing.

 With coordination of centre plate laying the rock bottom plates
consecutively as per drawing.
 Overlaps shall be maintained while the fit-up of a short-seam and long-
seam as per drawing.
 Temporary tack weld to be performed on the long-seam to avoid uneven
movements, while the fit-up and welding of short-seam.
 Short-seam welding is going to be performed alternatively to avoid
distortion.
 After the completion of short-seam welding, remove the temporary tack
on the long-seam by grinding to facilitate the long-seam fit-up.
 Minimum laps shall be maintained while the fit-up of long-seam as per
approved drawing.
 Hammering shall be performed top side on the plate if necessary. For
example three plates joining junction.
 Before starting the welding, steel channel shall be tacked along the long
seam to avoid distortion. After completion of short-seam welding then
long-seam welding is performed alternatively to avoid distortion.
 After completion of welding thoroughly clean the weld joint by wire
brushing and grinding.
  Sketch to annular plate joint shall be welded only after the shell to
bottom joint welding.
 All rock bottom plates joints vacuum box test shall be administered as
per the approved process and code.
 If any defect is found, the defect weld shall be removed by grinding and
re-weld then conducting the vacuum box test. Repeat the sequence until
the defect is cleared.

4.3 Erection of storage Tank shell plates

 After the completion of the welding of annular plates and bottom plates,
mark the tank inner radius on the annular plate.
 Fix some numbers of erection tools at the equal interval on the annular
plates and transfer within the tank diameter on the tools.
 The last two shell courses shall be erected by the conventional method.
 Remaining shell courses shall be erected by the jacking method.
 The rolled shell plates shall be shifted to the tank foundation area.
 Care shall be taken that the shell plate is erected to the diameter marked on
the annular plate. Jigs and fixtures shall be used to align the shell plates.
 Complete the fit-up except the ultimate joint which shall be fitted and
welded after completion of the welding of the opposite joints. It is to avoid
shrinkage.
 Peaking shall be checked at the top, middle and bottom of the vertical joints
by Templates. Plumpness shall be checked for verticality of the shell course
at every 60 degree and shall be within the tolerance. Tolerance is 1/200 of
the entire shell height (as per API 650).
 For perfect verticality, channel support shall be provided at the regular
interval of inside the shell course (3m to 5m).
 Tack weld of the fitted vertical joints shall be ground smooth. Offer for
inspection and obtain clearance from quality department.
 For the vertical fit-up complete the primary side welding by using qualified
welders.
 Take care while welding to avoid peaking and therefore the roundness
distortion.
 After completion of primary side welding, then back chip by grinding.
 Back-chipped grooves shall be offered for inspection before starting the
welding.
 Complete the back pass welding using qualified welders.
 Joint numbers and welder number shall be marked on the both sides of the
weld joint. Clean the welded joints from each side by wire brushing and
grinding.
 After completion of welding from each side remove all the temporary
fixtures and flush grind the tack weld (Do the weld refill wherever need).
 Check the plumpness, circumference and therefore the radius then offer for
the inspection.
 While erecting the subsequent course 3mm thickness spacers shall be kept
between the shell courses.
 Erection the channels shall be fixed between jacked shell course and to be
erected shell course plates at regular intervals to align and hold the last shell
in a vertical position.
 Start fit-up the vertical seam and horizontal seam. When complete the fit-up
work check to peaking at vertical joints and banding of horizontal joints.
 Complete welding of last course vertical seam, inside after back chip and
welding shall be following the horizontal seam then follow to as same as for
other shell courses.
 After completion of welding then weld visual, verticality and circumference
shall be verified.
 Check verticality of the last shell course, verticality (plumpness) tolerance
shall be as per API 650.
 While welding care shall be taken for banding and therefore the roundness.
When finish the back-chip grinding after start the back pass welding.
 Complete the two sides welding and clean the joints thoroughly from each
side by grinding and wire brushing. Check banding, plumpness and keep
record.
 Offer weld visual to the quality control, and mark the Radiography spots as
per the instruction and follow the radiography as per API 650 requirements.
 Spiral staircase erection shall be performed as per drawing including
brackets and avoiding fouling with welds.
 Remove all the temporary cleats and tack welds.
  After completion of the shell to the bottom outside weld visual inspection is
going to be performed to the concerned in charge.
 On completion of shell to bottom welding and all NDT complete, all erection
and welding work on the tank inside associated with the roof and roof
structure.
 Radiography of the vertical and horizontal joints shall be completed.
 Sketch to annular plate joint fit-up shall be performed after completing the
shell to bottom welds.
 Vacuum box test shall be performed for rock bottom plate short seam, long
seam and sketch to annular plate joint.

4.4 Erection of Roof Plates and Structure

 After completion of the highest two shell courses erection, fit-up, welding
and curb ring fit-up and welding shall be done.
 Erection the fabricated centre drum, roof truss and cross girders as per
drawing.
 Erect the roof structures and lay the roof plates as per drawing. While fit
from the short seams and long seams overlaps to be maintained as per
drawing.
 Welding or fastening the short seam and long seam by welding the
alternative joint mentioned within the drawing to stop the distortion.
 Roof nozzles and top shell nozzles fit-up and welding shall be carried out as
per the approved drawing and it is to be correlated with the primary piping
drawing.

4.5 Installation of Shell Attachments and Nozzle

 Flanges to pipe joint shall be prefabricated and required NDT shall be
completed before erection.
 Mark the Nozzle location as per drawings. Cut the openings by Gas cutting
after the proper inspection.
 Erect the Nozzle as per the orientation so the elevation shown within the
drawing. Install Reinforcement pads wherever required before nozzle
erection.
 Suitable supports and fixtures shall be provided to stop the distortion during
the welding.
 Orientation, elevation and projection shall be maintained as per drawing
and offer for the inspection clearance.
 Welding shall be as per WPS, and to be welded by qualified welders.
 The manhole neck shall be fabricated and therefore the longitudinal joint
shall be Liquid Penetrant Testing. All reinforcement pad weld shall be
pneumatically tested.
 All the shell nozzles finally weld from each side and reinforcement pad
welds shall be inspected visually and by Liquid Penetrant Testing.