installation and commissioning of api 650 tanks (presentation without audio)
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5/23/2018 Installation and Commissioning of API 650 Tanks (Presentation Without Audio)
API 650 TANKS
INSTALLATION and COMMISSIONINGbyMike Raine BSc MSc MIEAust AFIAMDirector, Engineering ManagerFuel Tank and Pipe
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5/23/2018 Installation and Commissioning of API 650 Tanks (Presentation Without Audio)
Process Water TanksFMG Cloudbreak Mine-site
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API 650 TANKS INSTALLATION
TANK BUNDS FOUNDATIONS/RING
BEAMS WELDING PROCEDURES
COMMISSIONING TANK STRAPPING NDT HYDROTESTING
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FLOOR PLATE LAYOUT STRAKE LAYOUT ROOF CONSTRUCTION ROOF LIFT
NOZZLE INSTALLATION SURFACE PREPARATION TOLERANCES
CONTROL PHILOSOPHY INSTRUMENTS
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Process Water Tanks, DieselStorage Tanks, Cloudbreak
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TANK BUNDS AS1940 mandates bunded storage for hydrocarbon storage
facilities. Bund volume shall not be less than 110% of thevolume of storage. For multiple tanks, multiple products the storage volume is
110% of the largest tank. Although each tank must be
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Bund Construction Earthen bund fully lined with a composite Geo-Fabric, Welded
HDPE liner, Geo Fabric Membrane installed on a select fill base Bund walls with a 45 Degress angle of repose covered with a
concrete filled revetment mattress. Revetment mattress can either be painted or covered with a layer
of concrete.
Bund liner is pneumatically leaked tested on the overlappingwelded seam.
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TANK BUND CONSTRUCTION1. Geo-Fabric HDPE Lined Bund.
2. Concrete filled revetment mattress prior tofinal coating.3. Compacted select fill providing a metre of
cover over the Geo-Fabric HDPE membrane.
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Tank Bund Construction
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Other forms of Bunding Self Bunded Tanks
Limits storage volumeand results in multipletanks.
Concrete Bunds
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Effective for a tank farmwith an array of small
tanks. Both methods cost
prohibitive on largevolume storage facilities.
Images courtesy of DRA Tank
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Foundation Ring Beam Construction
Tank foundations at typically of 3 types.
Concrete Ring Wall Asphalt
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FT&P almost exclusively build tanks on aconcrete ring wall foundation.
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Concrete Ring Beam Design Ring beams perform a variety of functions. A
critical aspect of ring beam design is whetherholding down bolts are required for windoverturning stability.
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ac ors n uenc ng e nee s or o ng ownbolts include; Cyclonic region and prevailing wind speeds. (AS/NZS
1170.2:2002) Weight of Tank (excluding roof and contents) Aspect ratio of the tank, tall versus squat to achieve the same
storage Client specifications.
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Ring Wall Components Reinforcing Bars Re-bar comprises ligatures placed on an
angular pattern with a maintained
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A total 8 to10 rolled circumferential lacebars located on the internal and externaldiameters of the ligatures.
Plywood board and rolled tubes make upthe remainder of the form.
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Ring Wall Components 30mm PVC pipes are installed at 4 angular locations
to provide weep holes leaking product. Tank earthing is facilitated by connecting the tankshell to the rebar.
The ring wall is back filled with select fill and
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compac e o m . Diesel is sprayed on the fill to prevent corrosion of the
underside of the floor plate. Bitumen board installed on top of the ring wall
providing a compressive membrane between it andthe floor plate.
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Construction of Ring Wall Ring beam foundation is excavated after the liner has
been installed and the bund has been backfilled. A 50mm layer of blinding is installed to provide a stable
base for the construction of the formworks. Establishin a stable level base/foundation is critical to
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achieving tight tolerances on the overall tank build.
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Ring Wall Construction
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Ring Wall Construction
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Holding Down Bolts Analysis
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Wind Forces, Overturning Moments
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Wind Forces, Overturning Moments
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Design of Anchor Bolts
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Holding Down bolt ArrangementRing Beam for HD Bolts Inverted Tee Ring Beam
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Holding Down Bolt ArrangementFEA of HD Arrangement Shell Bolting Arrangement
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Weep Hole, Earthling Strap
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Floor Plate Layout Typically floor plate ranges in thickness
from 6-10mm without the addition ofcorrosion allowance.
FT&P enerall utilise an offset over la in
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plate arrangement. Alternatively, an annular plate arrangement
is often used which allows for thicker plate
at the shell interface and simplifies floorreplacement.
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Floor Plate Layout
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Floor Plate
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AS1692 3.7 and Applicable Welding Code
For Cylindrical Vertical Tanks greater
than 4.5m in diameter AS1692nominates a Category 6 tank.
a egory an AS1692 nominates either BS EN 14015 API620 orAPI650.
Welding Standard AS1692 allows an Australian Standard to be
nominated in place if both purchaser and contractorare agreeable.
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Welding Standard Which code FT&P use ? AS3992 and Pre-qualified Procedures? AS1554
API650
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Welding Standard API650 derives the welding code from Section IX of the ASME code.
FT&P almost exclusively use
proce ures qua e o . API650 Visual Examination permissible limits are
commensurate with the build conditions.
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Visual Examination
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Vertical Down API650 Procedure
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Welding Procedures Weld Procedures Defined under ASME IX FCAW/Machine Welded Horizontals
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MMAW butt weld with backing plate for fillet
to butt weld transition as the floorapproaches the shell.
MMAW Iron Powder for fillet Welds on floor,roof, wind girder, compensating plates.
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Shell Plate ThicknessAppendix A, Determination of Shell Thickness
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Tank Aspect Ratio Tank Aspect Ratio is significant in the overall design of the
tank. In respect of tank holding down bolts, a squatter tank is
favourable. Increasing height increases static head which influences
.
Volume is proportional to Diameter Squared. Thuschanges in diameter have a great influence on height.
Squatter tanks are more economical on material.(Calculus minima question in TEE)
Increasing diameter is often restricted by space. Plate heights in either 3m or 3.2m thus preference fortanks over 6m high
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Aspect Ratio for 600kL Tank
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Shell Plate ThicknessAppendix A, Optional Design Basis for Small Tanks.
Appendix A allows joint efficiencies of either0.85 or 0.7 If 0.7 is used 42% additional plate thickness is
required. Joint efficiency of 0.7 provides a relaxation onNDT. Documented in Clause A3.4 of API650. By agreement of contractor and purchaser.
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Radiography RequirementPlate Thickness
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Radiography RequirementPlate Thickness
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Radiography RequirementPlate Thickness >25mm
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Radiography RequirementPlate Thickness
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Radiography RequirementRadiography Notes:
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Strake Layout
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Key Plates
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Location of Plates Shell plate horizontal and vertical
plate clearances are maintained bykey plates, shims and wedges.
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ey p a es are secure o e s e . Driven wedges maintain the gaps for
welding
Shims maintain the clearance on thehorizontal weld.
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Automatic Welder This style of welder used
for horizontal welds. The welding process is
controlled by anoscillator.
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welding parameters canbe controlled. The welder runs along a
magnetic flexible steeltrack.
Viable on larger tanks.
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Final Strakes
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Roof Construction
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Roof Construction Fuel Tank & Pipe often build the roof
on the ground and lift this on to thecompleted strakes.
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u y eng neere s u es aregenerated using Spacegass and otheranalytical methods.
Lifting lug design
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Spacegass FEA model.
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Lifting Lug Design
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Finished Roof Can
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Roof Lift
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Tolerances and DeviationsAPI 650 provides guidance.Typical client requirements Circumference
1.5 x D/1000 +30mm
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1.5 x D/1000 +20mm
Height and Horizontality of Plate Edge 40mm
Local Deviations Buckle height floor/roof plateD/1000 x (t+20)/t
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Verticality of the Tank
Tolerances and Deviations
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Tank Survey
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Tank Survey
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COMMISSIONING Tank Strapping
Tank Strapping is a method of measuring thedeviation of the tank from its cylindrical form. The method employs a laser and provides an
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accura e c rcum eren a pro e o e an a
different heights up the tank. Strapping data is then entered into the tank
gauging system providing an accurate means ofinterpolating the tank volume.
Strapping Data
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Strapping Data
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Non Destructive Engineering FT&P employ the following methods on tank welds.
Vacuum box testing.
Radiography (Usually on Tee's i.e. intersections of vertical and
horizontal welds)
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70%. (API 650)
Magnetic Particle Inspection (100% of Joints) Dye Penetrant (100% of Joints) Air Testing of compensating plates.
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MPI of Tank Welds
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HYDROTESTING Hydro testing
Subject to availability of clean water.
For diesel tanks hydro-testing subjects the tank to a structuralload higher than the service load due to difference in SG ofwater and Diesel.
Hydro Testing allows testing of tank settlement
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-(Vacuum Box, MPI, Dye Penetrant on every joint)
On a 1.75Ml tank, the cost of clean water at a remote mine-site was $0.40 per litre.
Pragmatism prevailed, and Hydrotesting excluded. FT&P tender exclusions include provision of clean water. FT&P have experienced considerable algae growth on tank
internal surfaces following hydro testing and resulting insignificant additional costs arising out the cleaning the tank.
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PV Vents/Safety Valves On diesel tanks, FT&P
install self desiccating
filters Filters prevent ingress of
moisture arising from the
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air humidity. Filters become clogged if
they are not maintained. This can create either a
vacuum or pressure
condition in the tank
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PV Vents/Safety Valves A vacuum condition can lead to catastrophic failure of a
tank. Mitigated by the PV Valve. A plastic bag secured over a tank vent during routine
maintenance led to tank failure in a UK refiner durin a
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crash cooling event (rain storm).
Pressure 0 KPa Gauge Vacuum 1.3 KPa Gauge Vent sizing in accordance with AS1940
FT&P use Shands and Jur PV valves or equivalent. Sizing of vents will be undertaken by manufacturer
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PV Vent
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Venting Requirements
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Venting Requirements
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Flow Curve for a Vacuum Vent
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Rossing Fuel Tank Collapse 2 x 1.2m Litre fuel Tanks failed due to
vacuum condition. DN150 Vents on each tank replaced by
.
Gravity equalisation between tanksresulted in vacuum condition.
Tank collapsed due to inappropriate
sizing of the breathers.
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Tank Failure (Vacuum Condition)
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Tank Failure (Vacuum)
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Tank Failure (Vacuum)
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Tank Failure
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Tank Failure
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CONTROL PHILOSOPHY Checks
Tank SelectionControl, duty. Tank Selection
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on ro , ng
High Level Alarm HH Alarm Double redundancy
of above. Low Level Arm
INSTRUMENTS
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Level Gauges FT&P use the OPW iSite system Accurate to 1 mm Provides temperature compensation for bulk
fluid temperature. (ATO Tax rebates)
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Level gauge use strapping data to calculate
volume. The gauge supports many soft level alarms that
can be used for a variety of purposes includingbackup HH, H, L, LL alarms and re-order levelvia the Ethernet link.
The system is approved by the EPA in Californiaas a leak detection system.
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INSTRUMENTS
Level Switches Reed switch used for High, High High
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e prov es ac up o e a ove.
Typically no other additionalinstruments are required.
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End of Presentation Thank you for your Attention!
Acknowledgements Michael King, .
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Paula West, Alcoa Ben Pisano Blake Thompson CDMS.
Questions
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About FT&P , $ 30
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FT&P Rail Loading
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FT&P Rail Unloading
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Contact DetailsMike RaineFuel Tank & Pipe Pty Ltd,Unit 4/7 Owen Road,Kelmscott WA 6111
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phone: (08) 9497 3499fax: (08) 9497 3409mobile: 0400 046010
email: [email protected]